Myrons Mopeds

Horsepower versions: There were three horsepower (speed) versionson ’75 to ’86 US-model Puch mopeds, 1.0 hp (20 mph), 1.5 hp (25 mph) and 2.0 hp (30 mph). Each US state had a different speed and power limit. A sticker on each side cover said the power (speed) version, but nowhere else did. Without that, the power version can be determined by inspection or measurement of each part and matching that to the specs in the chart below. The carburetor ID number is the easiest and most useful way to find the power version in the chart.

Top End Versions: There were four different top end versions, 7-fin on ’75-85 Maxi, 8-fin on ’78-86 Maxi Hi-Torque, 9-fin on ’78-82 Magnum, and 10-fin on ’83-86 Austro Daimler (Maxi Plus) and Dart.

1975-86 Models and Model Codes: Here the Puch models that share the same speed version parts are grouped together and given codes. 18 parts catalogs cover the 12 year range of US-model Puch mopeds and re-brands. 16 of 18 are shown. Not included are pre-1975 US-model Puch mopeds and motorcycles sold by Sears. Also not included are Puch remakes made after 1987 in Italy, Slovakia and Turkey.  

1978-82 Sears, JC Penney and Murray partnered with Puch to produce their own brands. Sears and JC Penney are made in Austria by Kromag. Murray is made in USA by Murray. The parts manuals do not have Puch part numbers and all Puch branding is removed from the actual bikes and parts, because they want to keep the true identity secret. Three lines of evidence allow the Puch part number translations. 1) The Puch Series B parts manual has the same illustrations and text format as Sears and Murray parts manuals. 2) Actual carburetors, intakes and exhausts from Sears Free Spirit, JC Penney or Murray show the identity agrees with Puch Series B. 3) Specifications for gaskets and intakes from Sears or Murray show the identity agrees with Puch Series B.  For other parts the translation from Sears, JC Penney or Murray part numbers to Puch part numbers is guessed, based on agreement with Puch Series B. 

 

SHEET FRAME MODELS
code   catalog   power   colors: 7-fin, 8-fin, 9-fin, 10-fin

75    Jul 76 1.0-2.0 ’75-76 Maxi-N, Maxi-S, Nostalgic

76    Oct 761.0-2.0 ’76-77 Rigid, Maxi, Maxi Sport, Newport

78    Mar 781.0-2.0 ’78 GN, Maxi
78r  Mar 781.0 hp  ’78 Maxi Luxe, Sport, Newport
78t   Mar 781.0 hp  ’78 Sport MkII
78L  Mar 781.5-2.0 ’78 Maxi Luxe, Sport, Newport
78T  Mar 781.5-2.0 ’78 Sport MkII

79    Jan 791.0-2.0 ’79 GN, Maxi
79r   Jan 791.0 hp  ‘79 Maxi Luxe, Sport, Newport L
79t   Jan 791.0 hp  ‘79 Sport MkII, Maxi II
79L Jan 79 1.5-2.0 ’79 Maxi Luxe, Sport, Newport L
79T Jan 79 1.5-2.0 ’79 Sport MkII
79T Jan 79 1.5-2.0 ’78-79 Maxi II

80    Jan 801.0-2.0 ’80-83 Maxi
80r   Jan 801.0 hp  ’80-83 Maxi Luxe
80t   Jan 801.0 hp  ’80-83 Sport MkII, Newport II
80L  Jan 801.5-2.0 ’80-83 Maxi Luxe
80T  Jan 801.5-2.0 ’80-83 Sport MkII, Newport II

84    Jan 841.0-2.0 ’84-85 Maxi to 7736972
84s  Jan 841.5-2.0 ’84-85 Maxi Sport LS to 2421596
84r   Jan 841.0 hp  ’84-84 Maxi Luxe
84t   Jan 841.0 hp  ’84-84 Sport MkII, Newport II
84L  Jan 841.5-2.0 ’84-84 Maxi Luxe
84T  Jan 841.5-2.0 ’84-84 Sport MkII, Newport II

84A  Jan 841.5-2.0 ’84-86 Austro Daimler (Maxi Plus) I
85T  Jan 851.5-2.0 ’84-86 Austro Daimler (Maxi Plus) II

85    Jan 851.5-2.0 ’85-86 Maxi from 7736973
85r   Jan 851.0 hp  ’85-85 Maxi Luxe
85t   Jan 851.0 hp  ’85-85 Sport MkII, Newport II
85L  Jan 851.5-2.0 ’85-85 Maxi Luxe
85T  Jan 851.5-2.0 ’85-85 Sport MkII, Newport II
86L  Jan 841.5-2.0 ’85-86 Maxi Sport LS from 2421597
86T  Jan 851.5-2.0 ’85-86 Maxi Sport LS II

 

TUBE FRAME MODELS
code   catalog   power   colors: 7-fin, 8-fin, 9-fin, 10-fin

78j    Jan 781.0-2.0 ’78-79 JC Penney Pinto, Swinger

78s   Jan 781.0-2.0 ’78 Sears Free Spirit

78K   Jul 781.0-2.0 ’78 Magnum XK
78M  Jul 781.0-2.0 ’78 Magnum MkII

79K  Aug 791.0-2.0 ’79 Magnum XK
79M Aug 791.0-2.0 ’79 Magnum MkII

80M Jan 801.0-2.0 ’80-82 Magnum MkII
80M Jan 801.0-2.0 ’80-81 Magnum II

80m  Jan 801.5 ’79-82 Murray 8315, 8415, 8515
80m  Jan 802.0 ’79-82 Murray 8320, 8420, 8520

81    Apr 811.5-2.0 ’80-82 Series B

81M Feb 811.0-2.0 ’81-82 Magnum LTD

83D  Jan 831.5-2.0 ’83-84 Dart

85C  Jan 861.5-2.0 ’85-86 Cobra
86C  Jan 861.5-2.0 ’85-86 Cobra II

 

 

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1975-86 Puch Speed Versions

10 things are different for 1.0, 1.5 or 2.0 hp versions.

1. Head: some might have more chamber volume
2. Head gasket: some are thicker, for lower compression
3. Piston: some are longer, restricting intake
4. Cylinder: some have restrictor plugs
5. Base gasket: some are thinner, for less port duration
6. Carburetor: some are smaller
7. Air filter: some have restrictor plugs
8. Intake pipe: some are smaller or restricted
9. Exhaust pipe: some have less holes inside
10. Sprockets: some are geared lower

 

How to upgrade to 2.0 hp specification:

This procedure is only for bikes where all of the parts are original.

1. Indentify the year and model of the bike. The year is on the ID plate. Here they are shown and explained. 

2. Look up your bike’s parts catalog and model code in the list above.

3. Then for each part in the list below, look at the color of the Puch part number for that model code. Green means the part is the same as on 2.0 hp versions. Black means it is not the same as on 2.0hp versions.

4. Change all of the parts with black part numbers to green specification, either by replacement or modification.

5. Unfortunately not all of the part specifications are known.

 

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1. Head

000.001.1111 color code years power  HEAD
349.410.0011 silver 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.410.0011 silver 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.410.0011 silver 78   ’78-78 1.0 GN, Maxi
349.410.0011 silver 79   ’79-79 1.0 GN, Maxi
349.410.0011 silver 80   ’80-83 1.0 Maxi
349.410.0011 silver 84   ‘84-85 1.0 Maxi
349.210.2011 black 78r  ‘78-78 1.0 Maxi Luxe, Newport
349.210.2011 black 78t  ‘78-78 1.0 Sport MkII
349.210.2011 black 79r  ‘79-79 1.0 Maxi Luxe, Newport L
349.210.2011 black 79t  ‘79-79 1.0 Sport MkII, Maxi II
349.210.2011 black 80r  ‘80-83 1.0 Maxi Luxe
349.410.0011 silver 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.410.0011 silver 76   ’76-77 1.5-2.0 Rigid, Maxi, Maxi Sport, Newport
349.410.0011 silver 78   ’78-78 1.5-2.0 GN, Maxi
349.410.0011 silver 78s    ’78-78 1.5-2.0 Sears Free Spirit
349.410.0011 silver 78j    ’78-79 1.5-2.0 JC Penney Pinto, Swinger
349.410.0011 silver 79   ’79-79 1.5-2.0 GN, Maxi
349.410.0011 silver 80   ’80-83 1.5-2.0 Maxi
349.410.0011 silver 81   ‘80-82 1.5-2.0 Series B
325.110.0011 silver 84   ‘84-84 1.5-2.0 Maxi
325.110.0011 silver 84s  ‘84-84 1.5-2.0 Maxi Sport LS to 2421596
349.310.4011 black 78L ’78-78 1.5-2.0 Maxi Luxe, Sport, Newport
349.310.4011 black 78T ’78-78 1.5-2.0 Sport MkII
349.310.4011 black 79L ’79-79 1.5-2.0 Maxi Luxe, Sport, Newport L
349.310.4011 black 79T ’79-79 1.5-2.0 Sport MkII
349.310.4011 black 79T ’78-79 1.5-2.0 Maxi II
349.310.4011 black 80L ’80-83 1.5-2.0 Maxi Luxe
349.310.4011 black 80T ’80-83 1.5-2.0 Sport MkII, Newport II
349.810.4011 black 84L ’84-85 1.5-2.0 Maxi Luxe
349.810.4011 black 84T ’84-85 1.5-2.0 Sport MkII, Newport II
349.710.4011 silver 85C ’85-86 1.5 Cobra
349.710.4011 silver 86C ’85-86 1.5 Cobra II
349.110.4011 silver 86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597
349.110.4011 silver 85   ’85-86 1.5-2.0 Maxi
349.110.4011 silver 86T ’85-86 1.5-2.0 Maxi Sport LS II 
349.110.4011 silver 85C ’85-86 2.0 Cobra
349.110.4011 silver 86C ’85-86 2.0 Cobra II
328.410.4011 black 78K  ’78-78 1.0-1.5-2.0 Magnum XK
328.410.4011 black 78M ’78-78 1.0-1.5-2.0 Magnum MkII
328.410.4011 black 79K  ’79-79 1.0-1.5-2.0 Magnum XK
328.410.4011 black 79M ’79-79 1.0-1.5-2.0 Magnum MkII
328.410.4011 black 80M ’80-82 1.0-1.5-2.0 Magnum MkII
328.710.4011 black 80M ’80-81 1.0-1.5-2.0 Magnum II
345.110.1011 silver 84A ’84-86 1.5 Austro-Daimler (Maxi Plus)
345.110.1011 silver 84T ’84-86 1.5 Austro-Daimler (Maxi Plus) II
345.110.0011 silver 84A ’84-86 2.0 Austro-Daimler (Maxi Plus)
345.110.0011 silver 84T ’84-86 2.0 Austro-Daimler (Maxi Plus) II

 

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2. Head Gasket

000.000.000 mm code years power  HEAD GASKET
349.110 none 0.0 78L ’78-78 1.5-2.0 Maxi Luxe, Sport, Newport
349.110 none 0.0 78T ’78-78 1.5-2.0 Sport MkII
349.110 none 0.0 79L ’79-79 2.0 Maxi Luxe, Sport, Newport L
349.110 none 0.0 79T ’79-79 2.0 Sport MkII
349.110 none 0.0 79T ’78-79 2.0 Maxi II
349.110 none 0.0 80T ’80-83 2.0 Sport MkII, Newport II
349.110.0041 0.4 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.110.0041 0.4 76   ’75-76 1.0 Rigid, Maxi, Maxi Sport, Newport
349.110.0041 0.4 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.110.0041 0.4 76   ’76-77 1.5-2.0 Rigid, Maxi, Maxi Sport, Newport
349.110.0041 0.4 78   ’78-78 1.5-2.0 GN, Maxi
349.110.0041 0.4 78t  ’78-78 1.0 Sport MkII
349.110.0041 0.4 79   ’79-79 1.5-2.0 GN, Maxi
349.110.0041 0.4 79t  ’79-79 1.0 Sport MkII
349.110.0041 0.4 80   ’80-83 1.5-2.0 Maxi
349.110.0041 0.4 81   ’80-82 1.5-2.0 Series B
349.110.0041 0.4 84   ’84-84 1.5-2.0 Maxi
349.110.0041 0.4 84s  ’84-84 1.5-2.0 Maxi Sport LS to 2421596
349.110.0041 0.4 85   ’85-86 2.0 Maxi
349.110.0041 0.4 85C ’85-86 2.0 Cobra
349.110.0041 0.4 86T ’85-86 2.0 Maxi Sport LS II
349.110.0041 0.4 86C ’85-86 2.0 Cobra II
349.110.0041 0.4 78K  ’78-78 1.0-2.0 Magnum XK
349.110.0041 0.4 78M ’78-78 1.0 & 2.0 Magnum MkII
349.110.0041 0.4 79K  ’79-79 1.0-2.0 Magnum XK
349.110.0041 0.4 79M ’79-79 1.0 & 2.0 Magnum MkII
349.110.0041 0.4 80M ’80-82 1.0 & 2.0 Magnum MkII
349.110.0041 0.4 80M ’80-82 1.0 & 2.0 Magnum II
349.110.0041 0.4 81M ’81-82 1.0 & 2.0 Magnum LTD
349.110.0041 0.4 83D ’83-84 2.0 Dart
349.110.0041 0.4 84A ’84-85 2.0 Austro Daimler (Maxi Plus)
349.110.0041 0.4 84T ’84-85 2.0 Austro Daimler (Maxi Plus) II
349.310.0041 0.8 85C ’85-86 1.5 Cobra
349.310.0041 0.8 86C ’85-86 1.5 Cobra II
349.310.0041 0.8 83D ’83-84 1.5 Dart
349.310.0041 0.8 84A ’84-85 1.5 Austro Daimler (Maxi Plus)
349.310.0041 0.8 84T ’84-85 1.5 Austro Daimler (Maxi Plus) II
328.110.8041 1.5 78r  ’78-78 1.0 Maxi Luxe, Newport
328.110.8041 1.5 78t  ’78-78 1.0 Sport MkII
328.110.8041 1.5 79r  ’79-79 1.0 Maxi Luxe, Newport L
328.110.8041 1.5 79t  ’79-79 1.0 Sport MkII, Maxi II
328.110.8041 1.5 80r  ’80-83 1.0 Maxi Luxe
328.110.8041 1.5 84   ’84-84 1.0 Maxi
328.110.8041 1.5 84r ’84-85 1.0 Maxi Luxe
328.110.8041 1.5 84   ’84-84 1.0 Maxi
328.110.8041 1.5 85   ’85-86 1.5 Maxi
328.110.8041 1.5 86L ’85-86 1.5 Maxi Sport LS from 2421597
328.110.8041 1.5 78L ’78-78 1.5 Maxi Luxe, Sport, Newport L
328.110.8041 1.5 78T ’78-78 1.5 Sport MkII
328.110.8041 1.5 79L ’79-79 1.5 Maxi Luxe, Sport, Newport L
328.110.8041 1.5 79T ’79-79 1.5 Sport MkII
328.110.8041 1.5 79T ’78-79 1.5 Maxi II
328.110.8041 1.5 80T ’80-83 1.5 Sport MkII, Newport II
328.110.8041 1.5 78M’78-78 1.5 Magnum MkII
328.110.8041 1.5 79M’79-79 1.5 Magnum MkII
328.110.8041 1.5 80M’80-82 1.5 Magnum MkII
328.110.8041 1.5 80M’80-82 1.5 Magnum II
328.110.8041 1.5 81M’81-82 1.5 Magnum LTD

None of these cylinders need a head gasket. New 8-fin ’78-83 2.0 hp models did not come with head gaskets. Remove the head gasket to upgrade to 2.0 hp specification. That provides a slight increase in compression ratio by reducing the combustion chamber volume.

 

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3. Piston

000.00.1111  lower oil  
000.0.11   rings  holes code years power  PISTON
349.110.0060 C 26  2 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic,
349.110.0060 C 26  2 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.110.0069 C 26  4 78   ’78-781.0 GN, Maxi
349.110.0069 C 26  4 78r  ’78-781.0 Maxi Luxe, Sport, Newport
349.110.0069 C 26  4 78t  ’78-781.0 Sport MkII
349.110.0069 C 26  4 78s  ’78-781.0 Sears Free Spirit
349.110.0069 C 26  4 79   ’79-791.0 GN, Maxi
349.110.0069 C 26  4 79r  ’79-791.0 Maxi Luxe, Sport, Newport
349.110.0069 C 26  4 79t ’79-791.0 Sport MkII, Maxi II
349.110.0069 C 26  4 80   ’80-83 1.0 Maxi
349.110.0069 C 26  4 80r  ’80-83 1.0 Maxi Luxe
349.110.0069 C 26  4 80t  ’80-83 1.0 Sport MkII, Newport II
349.110.1060 C 21  2 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.110.1060 C 21  2 76   ’76-77 1.5-2.0 Rigid, Maxi, Maxi Sport, Newport
349.110.1069 C 21  4 78   ’78-781.5-2.0 GN, Maxi
349.110.1069 C 21  4 78s  ’78-781.5-2.0 Sears Free Spirit
349.110.1069 C 21  4 79   ’79-791.5-2.0 GN, Maxi
349.110.1069 C 21  4 80   ’80-83 1.5-2.0 Maxi
349.110.1069 C 21  4 81   ’80-82 1.5-2.0 Series B
349.110.1069 C 21  4 84   ’84-84 1.5-2.0 Maxi
349.110.1069 C 21  4 84s  ’84-84 1.5-2.0 Maxi Sport LS to 2421596
350.310.0069 C 23  ? 78L ’78-78 1.5-2.0 Maxi Luxe, Sport, Newport
350.310.0069 C 23  ? 78T ’78-78 1.5-2.0 Sport MkII
349.210.5069 L  23  ? 79L ’79-79 1.5-2.0 Maxi Luxe, Sport, Newport L
350.310.0069 C 23  ? 79T ’79-79 1.5-2.0 Sport MkII
350.310.0069 C 23  ? 79T ’78-79 1.5-2.0 Maxi II
349.210.5069 L  23  ? 80L ’80-83 1.5-2.0 Maxi Luxe
349.210.5069 L  23  ? 80T ’80-83 1.5-2.0 Sport MkII, Newport II
350.310.0069 C 23  ? 78K  ’78-78 1.0-1.5-2.0 Magnum XK
350.310.0069 C 23  ? 78M ’78-78 1.0-1.5-2.0 Magnum MkII
350.310.0069 C 23  ? 79K  ’79-79 1.0-1.5-2.0 Magnum XK
350.310.0069 C 23  ? 79M ’79-79 1.0-1.5-2.0 Magnum MkII
350.310.0069 C 23  ? 80M ’80-83 1.0-1.5-2.0 Magnum II
350.310.0069 C 23  ? 80M ’80-83 1.0-1.5-2.0 Magnum MkII
350.310.0069 C 23  ? 81M ’81-82 1.0-1.5-2.0 Magnum LTD
345.110.0069 1 23  4 85   ’85-86 1.5-2.0 Maxi
345.110.0069 1 23  4 85C ’85-86 1.5-2.0 Cobra
345.110.0069 1 23  4 86C ’85-86 1.5-2.0 Cobra II
345.110.0069 1 23  4 86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597
345.110.0069 1 23  4 86T ’85-86 1.5-2.0 Maxi Sport LS II
345.110.0069 1 23  4 84A ’84-85 1.5-2.0 Austro-Daimler (Maxi Plus)
345.110.0069 1 23  4 84T ’84-85 1.5-2.0 Austro-Daimler (Maxi Plus) II

1.0 hp pistons for 7-fin cylinders have a 5 mm longer skirt (lower). That causes the intake port to open later and close sooner (less duration). Also some of the port is still blocked by the piston even at maximum opening (less area). It’s a simple matter to file or grind 5 mm off of the intake side piston skirt, to make it 21 mm from the bottom edge of the pin, the same as 2.0 hp specification. 8-fin and 10-fin cylinders never had 1.0 hp versions. 1.0 hp pistons for 9-fin cylinders are the same as 1.5 and 2.0 hp.

Rings:
C means two common type rings
L means upper L ring, lower common
1 means one common ring only

 

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4. Cylinder

000.001.1111 color code years power  CYLINDER with piston
349.810.0050 silver 00   restricted intake port
349.810.0050 silver 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.810.0050 silver 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.810.0050 silver 78   ’78-78 1.0 GN, Maxi
349.810.0050 silver 79   ’79-79 1.0 GN, Maxi
349.810.0050 silver 80   ’80-83 1.0 Maxi
349.810.0050 silver 84   ’84-85 1.0 Maxi to 7736972
349.310.0050 black 000 restricted intake port
349.310.0050 black 78r  ’78-78 1.0 Maxi Luxe, Sport, Newport
349.310.0050 black 78t  ’78-78 1.0 Sport MkII
349.310.2050 black 00    restricted intake port
349.310.2050 black 79r  ’79-79 1.0 Maxi Luxe, Sport, Newport
349.310.2050 black 79t  ’79-79 1.0 Sport MkII
349.310.2050 black 80r  ’80-83 1.0 Maxi Luxe
349.310.2050 black 80t  ’80-83 1.0 Sport MkII, Newport II
349.310.2050 black 84r  ’84-84 1.0 Maxi Luxe
349.310.2050 black 84t  ’84-84 1.0 Sport MkII, Newport II
349.310.2050 black 85r  ’85-85 1.0 Maxi Luxe
349.310.2050 black 85t  ’85-85 1.0 Sport MkII, Newport II
349.110.0050 silver 00   not restricted
349.110.0050 silver 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.110.0050 silver 76   ’76-77 1.5-2.0 Rigid, Maxi, Maxi Sport, Newport
349.110.0050 silver 78   ’78-78 1.5-2.0 GN, Maxi
349.110.0050 silver 78s  ’78-78 1.5-2.0 Sears Free Spirit
349.110.0050 silver 78j  ’78-79 1.5-2.0 JC Penney Pinto, Swinger
349.110.0050 silver 79   ’79-79 1.5-2.0 GN, Maxi
349.110.0050 silver 80   ’80-83 1.5-2.0 Maxi
349.110.0050 silver 80m’80-82 1.5-2.0 Murray 83xx, 84xx, 85xx
349.110.0050 silver 81   ’80-82 1.5-2.0 Series B
349.110.0050 silver 84   ’84-85 1.5-2.0 Maxi to 7736972
349.110.0050 silver 84s  ’84-85 1.5-2.0 Maxi Sport LS to 2421596
349.310.4050 black 00   not restricted
349.310.4050 black 78L ’78-78 1.5-2.0 Maxi Luxe, Sport, Newport
349.310.4050 black 78T ’78-78 1.5-2.0 Sport MkII
349.610.4050 black 000 replaces 349.310.4050
349.610.4050 black 79L ’79-79 1.5-2.0 Maxi Luxe, Sport, Newport L
349.610.4050 black 79T ’79-79 1.5-2.0 Sport MkII
349.610.4050 black 79T ’79-79 1.5-2.0 Maxi II
349.610.4050 black 80L ’80-83 1.5-2.0 Maxi Luxe
349.610.4050 black 80T ’80-83 1.5-2.0 Sport MkII, Newport II
349.610.4050 black 84L ’84-84 1.5-2.0 Maxi Luxe
349.610.4050 black 84T ’84-84 1.5-2.0 Sport MkII, Newport II
349.210.6050 silver 000 replaces 349.310.4050 and 349.610.4050
349.210.6050 silver 84L ’84-84 1.5-2.0 Maxi Luxe
349.210.6050 silver 84T ’84-84 1.5-2.0 Sport MkII, Newport II
349.210.6050 silver 85L ’85-85 1.5-2.0 Maxi Luxe
349.210.6050 silver 85T ’85-85 1.5-2.0 Sport MkII, Newport II
349.110.6050 silver 85   ’85-86 1.5-2.0 Maxi from 7736973
349.110.6050 silver 85C ’85-86 1.5-2.0 Cobra to 1505807
349.110.6050 silver 86C ’85-86 1.5-2.0 Cobra II to 1505807
349.110.6050 silver 86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597
349.110.6050 silver 86T ’85-86 1.5-2.0 Maxi Sport LS II
349.610.6050 silver 85C ’85-86 1.5-2.0 Cobra from 1505808
349.610.6050 silver 86C ’85-86 1.5-2.0 Cobra II from 1505808
328.710.4050 black 78K ’78-78 1.0-2.0 Magnum XK
328.710.4050 black 79K ’79-79 1.0-2.0 Magnum XK
328.310.2050 black 78M’78-78 1.0-2.0 Magnum MkII
328.310.2050 black 79M’79-79 1.0-2.0 Magnum MkII
328.310.2050 black 80M’80-82 1.0-2.0 Magnum MkII
328.910.2050 black 80M’80-82 1.0-2.0 Magnum II
334.110.0050 black 84A ’84-86 1.5-2.0 Austro Daimler (Maxi Plus)
334.110.0050 black 85T ’84-86 1.5-2.0 Austro Daimler (Maxi Plus) II

 

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5. Base Gasket

000.001.1111 mm code years power  BASE GASKET .
349.310.0131 0.5 all   ’75-86 1.0 all 7-fin models
349.310.0131 0.5 all   ’78-86 1.0 all 8-fin models
349.110.0131 1.0 all   ’75-86 1.5-2.0 all 7-fin models
349.110.0131 1.0 all   ’78-86 1.5-2.0 all 8-fin models
328.210.5131 0.3 all   ’78-82 1.0-1.5-2.0 all 9-fin models
328.310.0131 0.5 83D ’83-84 1.5-2.0 Dart
328.310.0131 0.5 84A ’84-86 1.5-2.0 Austro Daimler (Maxi Plus)
328.110.0131 1.0 84T ’84-86 1.5-2.0 Austro Daimler (Maxi Plus) II

 

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6. Carburetor

000.000.0000    mm 00 jet code  years  power  CARB 14 mm
349.415.5000 1/14/152 64 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
???.???.????    1/14/157 ??  78j  ’78-79 2.0 JC Penney Swinger
349.815.5000 1/14/160 64 76   ’76-77 2.0 Rigid, Maxi, Maxi Sport, Newport
349.815.5000 1/14/160 64 78   ’78-78 2.0 GN, Maxi
349.815.5000 1/14/160 64 79   ’79-79 2.0 GN, Maxi to 7705425
???.???.????    1/14/163 68 78s  ’78-78 2.0 Sears Free Spirit
349.115.6000 1/14/???  68 81   ’80-82 2.0 Series B
???.???.????    1/14/164 52 78s  ’78-78 1.0-1.5 Sears Free Spirit
349.915.5000 1/14/???  52 81   ’80-82 1.5 Series B
???.???.????    1/14/166 62 80m ’80-81 2.0 Murray 83xx, 84xx, 85xx
349.815.6000 1/14/185 64 80   ’79-83 2.0 Maxi from 7705426
349.815.6000 1/14/185 64 84   ’84-84 2.0 Maxi
349.815.6000 1/14/185 64 84s  ’84-84 2.0 Maxi Sport LS to 2421596
349.315.6500 1/14/203 70 86C ’85-86 1.5 Cobra II
349.515.5500 1/14/196 68 85C ’85-86 1.5-2.0 Cobra
349.515.5500 1/14/196 68 86C ’85-86 2.0 Cobra II

000.000.0000    mm 00 jet code  years  power  CARB 12 mm
???.???.????    1/12/279 00 000 modern remake
349.215.4000 1/12/292 54 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.215.4000 1/12/292 54 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.215.4000 1/12/292 54 78r  ’78-78 1.0 Maxi Luxe, Sport, Newport
349.315.4000 1/12/293 60 76   ’76-77 1.5 Rigid, Maxi, Maxi Sport, Newport
349.315.4000 1/12/293 60 78   ’78-78 1.5 GN, Maxi
349.315.4000 1/12/293 60 79   ’79-79 1.5 GN, Maxi to 7705250
349.315.4000 1/12/293 60 78L ’78-78 2.0 Maxi Luxe, Sport, Newport
349.415.4000 1/12/294 54 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.415.4000 1/12/294 54 78r  ’78-78 1.0 Maxi Luxe, Sport, Newport
349.415.4000 1/12/294 54 79r  ’79-79 1.0 Maxi Luxe, Sport, Newport L
349.415.4000 1/12/294 54 80   ’80-83 1.0 Maxi
349.415.4000 1/12/294 54 80r  ’80-83 1.0 Maxi Luxe
349.415.4000 1/12/294 54 84   ’84-84 1.0 Maxi
349.715.7000 1/12/297A 5080M’80-82 1.0 Magnum MkII
349.715.7000 1/12/297A 5080M’80-82 1.0 Magnum II
349.715.7000 1/12/297A 5081M’81-82 1.0 Magnum LTD
???.???.????    1/12/299 00 000  unknown
349.815.4000 1/12/300 48 78t  ’78-78 1.0 Sport MkII
349.815.4000 1/12/300 48 79t  ’79-79 1.0 Sport MkII, Maxi II
349.815.4000 1/12/300 48 80t  ’80-83 1.0 Sport MkII, Newport II
???.???.????    1/12/302 50 78j  ’78-79 1.0 JC Penney Swinger
349.115.7000 1/12/304 66 78L ’78-78 1.5 Maxi Luxe, Sport, Newport
349.215.7000 1/12/307 58 78T ’78-78 2.0 Sport MkII
349.215.7000 1/12/307 58 80   ’80-83 1.5 Maxi from 7705251
349.215.7000 1/12/307 58 84   ’84-84 1.5 Maxi
349.215.7000 1/12/307 58 84s  ’84-84 1.5 Maxi Sport LS to 2421596
349.215.7000 1/12/307 58 86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597
349.215.7000 1/12/307 58 80L ’80-83 2.0 Maxi Luxe
349.215.7000 1/12/307 58 85   ’85-86 1.5-2.0 Maxi
349.615.7000 1/12/309 48 80L ’80-83 1.5 Maxi Luxe
349.615.7000 1/12/309 48 80M’80-82 1.5 Magnum MkII
349.615.7000 1/12/309 48 80M’80-82 1.5 Magnum II
349.615.7000 1/12/309 48 81M’81-82 1.5 Magnum LTD
349.615.7000 1/12/310 48 79L ’79-79 1.5 Maxi Luxe, Sport, Newport L
349.315.8000 1/12/314 56 79T ’79-79 2.0 Sport MkII, Maxi II
349.315.8000 1/12/314 56 80T ’80-83 2.0 Sport MkII, Newport II
349.315.8000 1/12/314 56 86T ’85-86 1.5-2.0 Maxi Sport LS II
349.415.8000 1/12/316 64 78K ’78-78 2.0 Magnum XK
349.415.8000 1/12/316 64 79K ’79-79 2.0 Magnum XK
349.515.8000 1/12/317 50 78K ’78-78 1.5 Magnum XK
349.515.8000 1/12/317 50 79K ’79-79 1.5 Magnum XK
349.615.8000 1/12/318 50 78K ’78-78 1.0 Magnum XK
349.615.8000 1/12/318 50 79K ’79-79 1.0 Magnum XK
349.615.8000 1/12/318 50 78M’78-78 1.0 Magnum MkII
349.615.8000 1/12/318 50 79M’79-79 1.0 Magnum MkII
349.815.7000 1/12/321 50 79T ’79-79 1.5 Sport MkII
349.815.7000 1/12/321 50 79T ’78-79 1.5 Maxi II
349.815.7000 1/12/321 50 78j  ’78-79 1.5 JC Penney Pinto, Swinger
349.815.7000 1/12/321 50 80T ’80-83 1.5 Sport MkII, Newport II
349.715.8000 1/12/322 60 78M’78-78 2.0 Magnum MkII
349.715.8000 1/12/322 60 79M’79-79 2.0 Magnum MkII
349.715.8000 1/12/322 60 80M’80-82 2.0 Magnum MkII
349.715.8000 1/12/322 60 80M’80-82 2.0 Magnum II
349.715.8000 1/12/322 60 81M’81-82 2.0 Magnum LTD
349.815.8000 1/12/323 48 78M’78-78 1.5 Magnum MkII
349.815.8000 1/12/323 48 79M’79-79 1.5 Magnum MkII
???.???.????    1/12/339 52 83D ’83-84 1.5 Dart
???.???.????    1/12/340 54 83D ’83-84 2.0 Dart
345.315.6000 18.12.106 52 84A ’84-86 1.5 Austro Daimler (Maxi Plus)
345.315.6000 18.12.106 52 84T ’84-86 1.5 Austro Daimler (Maxi Plus) II
345.415.6000 18.12.107 54 84A ’84-86 2.0 Austro Daimler (Maxi Plus)
345.415.6000 18.12.107 54 84T ’84-86 2.0 Austro Daimler (Maxi Plus) II

Identification: Use this list to identify the bike model and speed version from knowing the year and carburetor ID number. 

Jet Size: Intake air restrictors located in the air filter box, before the carburetor, cause the jet size to be much smaller. Intake air restrictors located in the intake port or intake pipe, after the carburetor, cause the jet size to be the same or only slightly smaller. Besides the intake pipe and air filter box, other things that affect the jet size on a piston-port two-stroke engine are piston, cylinder, exhaust, and to a lesser degree, head and gaskets.  

 

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7. Air Filter

000.001.1111 fig code years  power  AIR FILTER for sheet frame
349.315.0700 20 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.315.0700 20 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.315.0700 20 78   ’78-78 1.0-1.5 GN, Maxi
349.315.0700 20 79   ’79-79 1.0-1.5 GN, Maxi
349.315.0700 20 80   ’80-83 1.0-1.5 Maxi
349.315.0700 20 78r  ’78-78 1.0-1.5 Maxi Luxe, Sport, Newport
349.315.0700 20 78t  ’78-78 1.0-1.5 Sport MkII
349.315.0700 20 79r  ’79-79 1.0-1.5 Maxi Luxe, Sport, Newport L
349.315.0700 20 79t  ’79-79 1.0-1.5 Sport MkII, Maxi II
349.315.0700 20 80r  ’80-83 1.0-1.5 Maxi Luxe
349.315.0700 20 78L ’78-78 1.5 Maxi Luxe, Sport, Newport
349.315.0700 20 78T ’78-78 1.5 Sport MkII
349.315.0700 20 79L ’79-79 1.5 Maxi Luxe, Sport, Newport L
349.315.0700 20 79T ’79-79 1.5 Sport MkII
349.315.0700 20 80L ’80-83 1.5 Maxi Luxe
349.315.0700 20 80T ’80-83 1.5 Sport MkII, Newport II
349.315.0700 20 84   ’84-84 1.0-1.5 Maxi
349.315.0700 20 84s  ’84-84 1.0-1.5 Maxi Sport LS to 2421596
349.315.0700 20 84L ’84-85 1.5 Maxi Luxe
349.315.0700 20 84T ’84-85 1.5 Sport MkII, Newport II
349.315.0700 20 86L ’85-86 1.5 Maxi Sport LS from 2421597
349.315.0700 20 86T ’85-86 1.5 Maxi Sport LS II
349.115.0700 10 75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.115.0700 10 76   ’76-77 1.5-2.0 Rigid, Maxi, Maxi Sport, Newport
349.115.0700 10 78   ’78-78 2.0 GN, Maxi
349.115.0700 10 79   ’79-79 2.0 GN, Maxi
349.115.0700 10 80   ’80-83 2.0 Maxi
349.115.0700 10 78L ’78-78 2.0 Maxi Luxe, Sport, Newport
349.115.0700 10 78T ’78-78 2.0 Sport MkII
349.115.0700 10 79L ’79-79 2.0 Maxi Luxe, Sport, Newport L
349.115.0700 10 79T ’79-79 2.0 Sport MkII
349.115.0700 10 80L ’80-83 2.0 Maxi Luxe
349.115.0700 10 80T ’80-83 2.0 Sport MkII, Newport II
349.115.0700 10 84   ’84-84 2.0 Maxi
349.115.0700 10 84s  ’84-84 2.0 Maxi Sport LS to 2421596
349.115.0700 10 84L ’84-85 2.0 Maxi Luxe
349.115.0700 10 84T ’84-85 2.0 Sport MkII, Newport II
349.115.0700 10 85S ’85-86 2.0 Maxi Sport LS from 2421597
349.115.0700 10 86T ’85-86 2.0 Maxi Sport LS II
345.115.5161 00 84A ’84-86 1.5-2.0 Austro Daimler (Maxi Plus)
345.115.5161 00 84T ’84-86 1.5-2.0 Austro Daimler (Maxi Plus) II

000.001.1111 fig code years  power   AIR FILTER for tube frame
321.215.2700 40 78K ’78-78 1.0-1.5 Magnum XK
321.215.2700 40 78M’78-78 1.0-1.5 Magnum MkII
321.215.2700 40 79K ’79-79 1.0-1.5 Magnum XK
321.215.2700 40 79M’79-79 1.0-1.5 Magnum MkII
321.215.2700 40 80M’80-82 1.0-1.5 Magnum MkII
321.215.2700 40 80M’80-82 1.0-1.5 Magnum II
321.215.2700 40 81M’81-82 1.0-1.5 Magnum LTD
321.215.2700 40 81   ’80-82 1.5 Series B
321.115.2700 30 78K ’78-78 2.0 Magnum XK
321.115.2700 30 78M’78-78 2.0 Magnum MkII
321.115.2700 30 79K ’79-79 2.0 Magnum XK
321.115.2700 30 79M’79-79 2.0 Magnum MkII
321.115.2700 30 80M’80-82 2.0 Magnum MkII
321.115.2700 30 80M’80-82 2.0 Magnum II
321.115.2700 30 81M’81-82 2.0 Magnum LTD
321.415.2700 50 81   ’80-82 2.0 Series B
321.415.2700 50 85C ’85-86 1.5-2.0 Cobra
321.415.2700 50 86C ’85-86 1.5-2.0 Cobra II

 

Restrictors: Intake air silencer/filter assemblies #20 and #40, for 1.0 or 1.5 hp versions, contain restrictor plugs #4 and #44. Remove the pressed in plugs to convert the air box to 2.0 hp version. This must be done along with the 2.0 hp carburetor changes which include a bigger jet.

 

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8. Intake Pipe

000.001.11 base carb code years  power  INTAKE PIPE 1-speed 
349.215.1301 12  12  75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.215.1301 12  12  76   ’76-77 1.0-1.5 Rigid, Maxi, Maxi Sport, Newport
349.215.1301 12  12  78   ’78-78 1.0-1.5 GN, Maxi
349.215.1301 12  12  000 ’78-78 1.0 and 2.0 Maxi Luxe, Sport
349.215.1301 12  12  78K ’78-78 1.0 and 2.0 Magnum XK
349.215.1301 12  12  79K ’79-79 1.0 and 2.0 Magnum XK
349.115.1301 Sq  14  75   ’75-76 1.5-2.0 Maxi-N, Maxi-S, Nostalgic
349.115.1301 Sq  14  76   ’76-77 2.0 Rigid, Maxi, Maxi Sport, Newport
349.115.1301 Sq  14  78   ’78-78 2.0 GN, Maxi  349.114.1301 = 3135
349.115.1301 Sq  14  78s  ’78-78 2.0 Sears Free Spirit
349.115.1301 Sq  14  78j   ’78-79 2.0 JC Penney Pinto, Swinger
349.115.1301 Sq  14  80m’79-82 2.0 Murray 8320, 8420, 8421, 8520
349.115.1301 Sq  14  81   ’80-82 1.5-2.0 Series B
3135, 3206 0  Sq  8.5 78s  ’78-78 1.5 Sears Free Spirit
3135, 3206 0  Sq  8.5 78j   ’78-79 1.5 JC Penney Pinto, Swinger
3135, 3206 0  Sq  8.5 80m’79-82 1.5 Murray 8315, 8415, 8416, 8515
3135, 3205 0  Sq  6.7 78s  ’78-78 1.0 Sears Free Spirit
3135, 3205 0  Sq  6.7 78j   ’78-79 1.0 JC Penney Pinto, Swinger
349.415.1301 12 9 12 000 ’78-78 1.5 Maxi Luxe, Sport
349.415.1301 12 9 12 78K ’78-78 1.5 Magnum XK
349.415.1301 12 9 12 79K ’79-79 1.5 Magnum XK
349.215.3301 12  12  79   ’79-79 1.0-1.5 GN, Maxi replaces 349.215.1301
349.215.3301 12  12  79r  ’79-79 1.0 Maxi Luxe, Sport, Newport L
349.215.3301 12  12  79L ’79-79 1.5 Maxi Luxe, Sport, Newport L
349.215.3301 12  12  80   ’80-83 1.0-1.5 Maxi
349.215.3301 12  12  84   ’84-85 1.0-1.5 Maxi
349.215.3301 12  12  84r  ’84-84 1.0 Maxi Luxe
349.215.3301 12  12  84L ’84-84 1.5 Maxi Luxe
349.215.3301 12  12  85   ’85-86 1.5 Maxi
349.215.3301 12  12  85r  ’85-85 1.0 Maxi Luxe
349.215.3301 12  12  85L ’85-85 1.5 Maxi Luxe
349.115.3301 14  14  79   ’79-79 2.0 GN, Maxi replaces 349.115.1301
349.115.3301 14  14  79L ’79-79 2.0 Maxi Luxe, Sport, Newport L
349.115.1301 14  14  80   ’80-83 2.0 Maxi
349.115.1301 14  14  80L ’80-83 2.0 Maxi Luxe
349.115.1301 14  14  84   ’84-85 2.0 Maxi
349.115.1301 14  14  84s  ’84-85 1.5-2.0 Maxi Sport LS to 2421596
349.115.1301 14  14  84L ’84-84 2.0 Maxi Luxe
349.115.1301 14  14  85   ’85-86 2.0 Maxi
349.115.1301 14  14  85L ’85-84 2.0 Maxi Luxe
349.115.1301 14  14  85C ’85-86 1.5-2.0 Cobra
349.115.1301 14  14  86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597

 

000.001.11 base carb code years  power  INTAKE PIPE 2-speed
321.615.6301 12  8.5 78T ’78-78 1.5 Sport MkII
321.415.6301 12  12  78t  ’78-78 1.0 Sport MkII
321.415.6301 12  12  78T ’78-78 2.0 Sport MkII
321.415.6301 12  12  79t  ’79-79 1.0 Sport MkII, Maxi II
321.415.6301 12  12  79T ’79-79 1.5 Sport MkII
321.415.6301 12  12  79T ’79-79 1.5 Maxi II
321.415.6301 12  12  80t  ’80-83 1.0 Sport MkII, Newport II
321.415.6301 12  12  80T ’80-83 1.5 Sport MkII, Newport II
321.415.6301 12  12  80M’80-81 1.0-2.0 Magnum II
321.415.6301 12  12  84t  ’84-84 1.0 Sport MkII, Newport II
321.415.6301 12  12  84T ’84-84 1.5 Sport MkII, Newport II
321.315.6301 14  14  79T ’79-79 2.0 Sport MkII, Maxi II
321.315.6301 14  14  80T ’80-83 2.0 Sport MkII, Newport II
321.315.6301 14  14  84T ’84-84 2.0 Sport MkII, Newport II
321.315.6301 14  14  86T ’85-86 1.5-2.0 Sport LS II
321.315.6301 14  14  86C ’85-86 1.5-2.0 Cobra II

000.001.11 base carb code years  power  INTAKE 1-sp oil injection
349.215.4032 14  14  000 ’78-78 1.0 and 2.0 Newport (oil inj)
349.315.4032 12  12  000 ’78-78 1.5 Newport (oil injection)

000.001.11 base carb code years  power  INTAKE 2-sp oil injection
349.815.6302 12  12  78M’78-78 1.0-2.0 Magnum MkII (oil inj)
349.815.6302 12  12  79M’79-79 1.0-2.0 Magnum MkII (oil inj)
349.815.6302 12  12  80M’80-82 1.0-2.0 Magnum MkII (oil inj)

Two-speed intake pipes are noticeably taller and slightly longer than 1-speed intakes, because the 2-speed engine case places the cylinder lower and slightly forward. The difference in intake dimensions equals the difference in cylinder position, because the carburetor is in the same position relative to the frame.

Oil injection intake pipes have a oil hose spigot.

 

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9. Exhaust Pipe

EXHAUST FRONT PIPE left side 1-speed ∅26 seal ring
000.001.1111 ∅P H code years  power  H is # of holes, grey is unsure
349.416.0012 18 1 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
349.416.0012 18 1 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.416.0012 18 1 78   ’78-78 1.0 GN, Maxi
349.416.0012 18 1 78r  ’78-78 1.0 Maxi Luxe, Sport, Newport
349.416.0012 18 1 79   ’79-79 1.0 GN, Maxi
349.416.0012 18 1 79r  ’79-79 1.0 Maxi Luxe, Sport, Newport L
349.416.0012 18 1 80   ’80-83 1.0 Maxi
349.416.0012 18 1 80r  ’80-83 1.0 Maxi Luxe
349.416.0012 18 1 84   ’84-84 1.0 Maxi
349.416.0012 18 1 84r  ’84-84 1.0 Maxi Luxe
349.416.0012 18 1 85r  ’85-85 1.0 Maxi Luxe
349.116.8012 22 2 75   ’75-76 1.5 Maxi-N, Maxi-S, Nostalgic
349.116.8012 22 1 76   ’76-77 1.5 Rigid, Maxi, Maxi Sport, Newport
349.116.8012 22 1 78   ’78-78 1.5 GN, Maxi
349.116.8012 22 1 79   ’79-79 1.5 GN, Maxi
349.116.8012 22 1 80   ’80-83 1.5 Maxi
349.116.8012 22 1 84   ’84-84 1.5 Maxi
349.616.0012 22 4 75   ’75-76 2.0 Maxi-N, Maxi-S, Nostalgic
349.616.0012 22 4 76   ’76-77 2.0 Rigid, Maxi, Maxi Sport, Newport
349.616.0012 22 4 78   ’78-78 2.0 GN, Maxi
349.616.0012 22 4 78L ’78-78 2.0 Maxi Luxe, Sport, Newport
349.616.0012 22 4 79   ’79-79 2.0 GN, Maxi
349.616.0012 22 4 79L ’79-79 2.0 Maxi Luxe, Sport, Newport L
349.616.0012 22 4 80   ’80-83 2.0 Maxi
349.616.0012 22 4 80L ’80-83 2.0 Maxi Luxe
349.616.0012 22 4 84   ’84-84 2.0 Maxi
349.616.0012 22 4 84L ’84-85 2.0 Maxi Luxe
349.916.0012 22 2 78L ’78-78 1.5 Maxi Luxe, Sport, Newport
349.816.0012 22 2 79L ’79-79 1.5 Maxi Luxe, Sport, Newport L
349.816.8012 22 1 80L ’80-83 1.5 Maxi Luxe
349.816.8012 22 1 84L ’84-84 1.5 Maxi Luxe
349.816.8012 22 1 85L ’85-85 1.5 Maxi Luxe
111.000.3049 22 0 78s  ’78-78 1.0 Sears Free Spirit
111.000.3049 22 0 78j  ’78-79 1.0 JC Penney Pinto, Swinger
111.000.3091 22 2 78s  ’78-78 1.5-2.0 Sears Free Spirit
111.000.3091 22 4 78j  ’78-79 1.5-2.0 JC Penney Pinto, Swinger
111.000.3091 22 4 80m’80-81 1.5-2.0 Murray 83xx, 84xx, 85xx
321.216.7012 22 2 81   ’81-82 1.5-2.0 Series B  = 3091?

 

4-hole versus 1-hole: The purpose of the holes is not for more or less flow. The holes allow reflected (negative) sonic pulses (pops!) to travel back up the head pipe to help draw out exhaust and draw in intake at the same time. More hole area makes more power. 

Hole location: The farther the holes are from the cylinder, the longer is the travel time of the negative sonic pulse (pop!), so the beneficial effect occurs at a lower rpm. That is why the 20mph version holes are near the rear, and the 30mph holes are near the front. 

EXHAUST FRONT PIPE left side 2-speed ∅26 seal ring
000.001.1111 ∅P H code years  power  H is # of holes, grey is unsure
349.516.6012 18 1 78t  ’78-78 1.0 Sport MkII
349.516.6012 18 1 79t  ’79-79 1.0 Sport MkII, Maxi II
349.516.6012 18 1 80t  ’80-83 1.0 Sport MkII, Newport II
349.516.6012 18 1 84t  ’84-84 1.0 Sport MkII, Newport II
349.516.6012 18 1 85t  ’85-85 1.0 Sport MkII, Newport II
349.616.6012 22 2 78T ’78-78 1.5 Sport MkII
349.616.6012 22 1 79T ’79-79 1.5 Sport MkII
349.616.6012 22 1 79T ’79-79 1.5 Maxi II
349.616.6012 22 1 80T ’80-83 1.5 Sport MkII, Newport II
349.616.6012 22 1 84T ’84-84 1.5 Sport MkII, Newport II
349.616.6012 22 1 85T ’85-85 1.5 Sport MkII, Newport II
321.416.6012 22 4 78T ’78-78 2.0 Sport MkII
321.416.6012 22 4 79T ’79-79 2.0 Sport MkII
321.416.6012 22 4 79T ’79-79 2.0 Maxi II
321.416.6012 22 4 80T ’80-83 2.0 Sport MkII, Newport II
321.416.6012 22 4 84T ’84-84 2.0 Sport MkII, Newport II
321.416.6012 22 4 85T ’85-85 2.0 Sport MkII, Newport II

 

1. Puch 1-speed exhaust on a 2-speed bike
2. How to tell the type, 1 or 2 speed
3. A third type, not yet identified 

The 2-speed cylinder is about 10 mm lower and 7 mm farther forward than a 1-speed cylinder. To make a 1-speed exhaust fit a 2-speed, the flange has to be re-angled by grinding to raise the rear pipe, the frame mount hole widened forward, and the pipe mount hole widened rearward.

’75-83 and some ’84: On these models with a 26mm ID seal ring, the tail pipe had only one mount hole. It was only slightly slotted, not enough to allow the 1 and 2 speed engines to use the same front exhaust pipe. 

’85-86 and some ’84: On these models with a 22mm ID seal ring, the tail pipe had several mount slots. That allowed the 1 and 2 speed front pipes to be the same dimensions.

 

EXHAUST FRONT PIPE left side 1- or 2-speed ∅22 seal ring
0000.001.1111 ∅P H code years  power H is # of holes, grey is unsure
349.516.7012 22 1 84s  ’84-84 1.5 Maxi Sport LS to 2421596
349.816.7012 22 2 85   ’85-86 1.5 Maxi
349.816.7012 22 1 86L ’84-86 1.5 Maxi Sport LS from 2421597
321.316.5012 22 2 86T ’85-86 1.5 Maxi Sport LS II
322.216.2012 22 2 85C ’85-86 1.5 Cobra
322.216.2012 22 1 86C ’85-86 1.5 Cobra II
349.116.9512 22 4 84s  ’84-84 2.0 Maxi Sport LS to 2421596
349.616.7012 22 4 85   ’85-86 2.0 Maxi
349.616.7012 22 4 86L ’84-86 2.0 Maxi Sport LS from 2421597
321.616.5012 22 4 86T ’85-86 2.0 Maxi Sport LS II
322.116.2012 22 4 85C ’85-86 2.0 Cobra
322.116.2012 22 4 86C ’85-86 2.0 Cobra II

 

EXHAUST FRONT PIPE right side 1- or 2-speed ∅22 seal ring
000.001.1111 ∅P H code years  power  H is # of holes, grey is unsure
345.216.1012 22 1 84A ’84-86 1.5 Austro Daimler (Maxi Plus)
345.216.1012 22 1 84T ’84-86 1.5 Austro Daimler (Maxi Plus) II
345.316.1012 22 4 84A ’84-86 2.0 Austro Daimler (Maxi Plus)
345.416.1012 22 4 84T ’84-86 2.0 Austro Daimler (Maxi Plus) II

 

EXHAUST FRONT PIPE left side 1- or 2-speed Magnum
000.001.1111 ∅P H code  years  power H is # of holes, grey is unsure
321.316.8012 00 0 78K  ’78-78 1.0 Magnum XK
321.316.8012 00 0 79K  ’79-79 1.0 Magnum XK
321.216.8012 25 6 78K  ’78-78 1.5-2.0 Magnum XK
321.216.8012 25 6 79K  ’79-79 1.5-2.0 Magnum XK
321.216.8012 00 0 78M ’78-78 1.0 Magnum MkII
321.216.8012 00 0 79M ’79-79 1.0 Magnum MkII
321.216.8012 00 0 80M ’80-83 1.0 Magnum II
321.216.8012 00 0 80M ’80-83 1.0 Magnum MkII (black)
321.516.8012 25 2 78M ’78-78 1.5 Magnum MkII
321.516.8012 25 2 79M ’79-79 1.5 Magnum MkII
321.516.8012 25 2 80M ’80-83 1.5 Magnum II
321.516.8012 25 2 80M ’80-83 1.5 Magnum MkII (black)
321.416.8012 25 6 78M ’78-78 2.0 Magnum MkII
321.416.8012 25 6 79M ’79-79 2.0 Magnum MkII
321.416.8012 25 6 80M ’80-83 2.0 Magnum II
321.416.8012 25 6 80M ’80-83 2.0 Magnum MkII (black)

Flange angle: The Magnum 9-fin cylinder has an angled exhaust flange, unlike the 7-fin and 8-fin cylinders which have horizontal flanges. So the 9-fin front pipe has a little less curve in it.

 

 

---

10. Sprockets

000.000.0000  teeth 0 code years power  sprocket plain
000.561.1322 13x45T 75   ’75-76 1.0 Maxi-N, Maxi-S, Nostalgic
000.561.1322 13x45T 76   ’76-77 1.0 Rigid, Maxi, Maxi Sport, Newport
349.113.0141 14x45T 75   ’75-76 1.5 Maxi-N, Maxi-S, Nostalgic
349.113.0141 14x45T 76   ’76-77 1.5 Rigid, Maxi, Maxi Sport, Newport
349.113.0161 16x45T 75   ’75-76 2.0 Maxi-N, Maxi-S, Nostalgic
349.113.0161 16x45T 76   ’76-77 2.0 Rigid, Maxi, Maxi Sport, Newport
000.000.0000  teeth 0 code years power  sprocket rubber coated
000.150.1036 11x45T 78   ’78-78 1.0 NY GN, Maxi
000.150.1036 11x45T 78r  ’78-78 1.0 NY Maxi Luxe, Sport, Newport
000.150.1036 11x45T 79   ’79-79 1.0 NY GN, Maxi
000.150.1036 11x45T 79r  ’79-79 1.0 NY Maxi Luxe, Sport, Newport
000.150.1036 11x45T 80   ’80-83 1.0 NY Maxi
000.150.1036 11x45T 80r  ’80-83 1.0 NY Maxi Luxe
000.150.1036 11x45T 84   ’84-84 1.0 NY Maxi
000.150.1036 11x45T 84r  ’84-84 1.0 NY Maxi Luxe
349.113.1132 13x45T 78   ’78-78 1.0 GN, Maxi
349.113.1132 13x45T 78r  ’78-78 1.0 Maxi Luxe, Sport, Newport
349.113.1132 13x45T 78s  ’78-78 1.0-1.5 Sears Free Spirit
349.113.1132 13x45T 78K ’78-78 1.0 Magnum XK
349.113.1132 13x45T 79   ’79-79 1.0 GN, Maxi
349.113.1132 13x45T 79r  ’79-79 1.0 Maxi Luxe, Sport, Newport L
349.113.1132 13x45T 79K ’79-79 1.0 Magnum XK
349.113.1132 13x45T 80   ’80-83 1.0 Maxi
349.113.1132 13x45T 80r  ’80-83 1.0 Maxi
349.113.1132 13x45T 81   ’80-82 1.5 Series B
349.113.1132 13x45T 80m 79-82 1.5 Murray 8315, 8415, 8515
349.113.1132 13x45T 84   ’84-85 1.0 Maxi to 7736972
349.113.1132 13x45T 84r  ’84-84 1.0 Maxi Luxe
349.113.1142 14x45T 78   ’78-78 1.5 GN, Maxi
349.113.1142 14x45T 78K ’78-78 1.5 Magnum XK
349.113.1142 14x45T 79   ’79-79 1.5 GN, Maxi
349.113.1142 14x45T 79K ’78-78 1.5 Magnum XK
349.113.1142 14x45T 80   ’80-83 1.5 Maxi
349.113.1142 14x45T 84   ’84-85 1.5 Maxi to 7736972
349.113.1142 14x45T 84s  ’84-85 1.5 Maxi Sport LS to 2421596
349.113.1152 15x45T 78s  ’78-78 2.0 Sears Free Spirit
349.113.1152 15x45T 78L ’78-78 1.5 Maxi Luxe, Sport, Newport L
349.113.1152 15x45T 79L ’79-79 1.5 Maxi Luxe
349.113.1152 15x45T 80L ’80-83 1.5 Maxi Luxe
349.113.1152 15x45T 80m 79-82 2.0 Murray 8320, 8420, 8520
349.113.1152 15x45T 81   ’80-82 2.0 Series B
349.113.1152 15x45T 84s  ’84-85 2.0 Maxi Sport LS to 2421596
349.113.1152 15x45T 84L ’84-84 1.5 Maxi Luxe
349.113.1152 15x45T 85   ’85-86 2.0 Maxi from 7736973
349.113.1162 16x45T 78   ’78-78 2.0 GN, Maxi
349.113.1162 16x45T 78K ’78-78 2.0 Magnum XK
349.113.1162 16x45T 79   ’79-79 2.0 GN, Maxi
349.113.1162 16x45T 79K ’78-78 2.0 Magnum XK
349.113.1162 16x45T 80   ’80-83 2.0 Maxi
349.113.1162 16x45T 84   ’84-85 2.0 Maxi to 7736972
349.113.1162 16x45T 84L ’84-84 2.0 Maxi Luxe
349.113.1162 16x45T 85L ’85-85 2.0 Maxi Luxe
349.113.1162 16x45T 86L ’85-86 1.5-2.0 Maxi Sport LS from 2421597
349.113.1182 18x45T 78t  ’78-78 1.0 Sport MkII
349.113.1182 18x45T 78M’78-78 1.0 Magnum MkII
349.113.1182 18x45T 79t  ’79-79 1.0 Sport MkII, Maxi II
349.113.1182 18x45T 79M’79-79 1.0 Magnum MkII
349.113.1182 18x45T 80t  ’80-83 1.0 Sport MkII, Newport II
349.113.1182 18x45T 80M’80-82 1.0 Magnum MkII
349.113.1182 18x40T 80M’80-81 1.0 Magnum II
349.113.1182 18x45T 84t  ’84-84 1.0 Sport MkII, Newport II
349.113.1182 18x45T 85t  ’85-85 1.0 Sport MkII, Newport II
349.113.1182 18x40T 78T ’78-78 1.5-2.0 Sport MkII
349.113.1182 18x40T 78M’78-78 1.5-2.0 Magnum MkII
349.113.1182 18x40T 79T ’79-79 1.5-2.0 Sport MkII
349.113.1182 18x40T 79T ’79-79 1.5-2.0 Maxi II
349.113.1182 18x40T 79M’79-79 1.5-2.0 Magnum MkII
349.113.1182 18x40T 80T ’80-83 1.5-2.0 Sport MkII, Newport II
349.113.1182 18x40T 80M’80-82 1.5-2.0 Magnum MkII
349.113.1182 18x40T 80M’80-81 1.5-2.0 Magnum II
349.113.1182 18x40T 84T ’84-84 1.5-2.0 Sport MkII, Newport II
349.113.1182 18x40T 85T ’85-85 1.5-2.0 Sport MkII, Newport II
349.113.1182 18x40T 86T ’85-86 1.5-2.0 Maxi Sport LS II

 

 

 

 

This is the old version that has been replaced.

 

 

 

 

 

 

 

 

 

 

 

USA Models 1974-1986

 

All models use 50:1 pre-mix, two-stroke oil and gas, except those that say “oil injection”.
Modern unleaded gasoline is OK to use. The “do not use unleaded” label is obsolete.
All US models have automatic transmissions. Most are one-speed, but some are two-speed.

The plain Maxi and Rigid models have the 7-side-fin “low-torque” engine top end.
The other step-thrus have a 8-side-fin “hi-torque” top end (head, cylinder, intake and carb).
The Magnum top tank models have the 9-side-fin “Magnum” engine top end.

Each model came in three horsepower versions, different for each US state.

wide spoke wheel means rim is 1.35 inner width,
thin spoke wheel means rim is 1.1 inner width.
ff means front fender. A thin front fender needs a thin 2.00-17 tire.

 

 

---

1974-75  models in July 1976 parts catalog

1974-75 Maxi S  yellow, apple green, white
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet frame with Suspension
CEV 8177 light switch, CEV 9350 rear light
Merit 342 rounded chrome engine stop switch

 

 

---

1976 models in July 1976 parts catalog

1976 Maxi N   red, white
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet “hard tail” frame, No rear suspension
CEV 8177 light switch, CEV 9350 rear light
Merit 342 rounded chrome engine stop switch

1976 Maxi S
yellow, white, violet, silver, apple green
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet frame with Suspension
CEV 8177 light switch, CEV 9350 rear light
Merit 342 rounded chrome engine stop switch

1976 Nostalgic
black, black/gold, black/red, black/gold/red
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
CEV 8177 light switch, ULO 250 rear light
Merit 342 rounded chrome engine stop switch

 

 

 

 

 

 

 

 

 

 

---

1977 models in Oct 1976 parts catalog

1977 Rigid   red  (formerly Maxi N)
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet “hard tail” frame
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches

1977 Maxi 
candy red, candy blue, white, apple green, yellow
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches 

1977 Maxi Sport  silver, yellow  
7-fin, new mag wheels, wide ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches

1977 Newport
champagne, burgundy (was called Nostalgic)
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

---

1978 models in Mar ’78 and Jan ’79 catalogs

1978 GN   red  (formerly Rigid)
7-fin. thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet hard tail, Merit 342, 343 switches
Magura silver controls, wrap-around throttle
CEV 2157 headlight, ULO 250 rear light 

1978 Maxi   candy red, candy blue
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 2157 headlight, ULO 250 rear light 

1978 Maxi Luxe emerald green, silver, burgundy
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 2157 headlight, ULO 250 rear light 

1978 Maxi Sport   silver
8-fin, “snowflake” wheels, wide ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 2157, ULO 250, same as 1977

1978 Sport   pearl green
8-fin, “snowflake” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 2157 headlight, ULO 250 rear light 

1978 Newport  pearl blue 
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 2157 headlight, ULO 250 rear light 

1978 Newport (oil injection) pearl blue, rose  
8-fin auto-start, wide sp. whls, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 2157 headlight, CEV 9417 rear light

1978 Newport L   white, black  
8-fin, wide sp. whls, wide ff, 2.25-17
Magura black controls, sliding-block
Merit 342A, 343A switches
CEV 2157 headlight, CEV 9417 rear light

1978 Maxi II   Inca gold (two speed)
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342, 343 rounded chrome switches
CEV 2157 headlight, CEV 9417 rear light

1978 Sport MkII  pearl green, black (two speed)
8-fin, “snowflake” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 2157 headlight, ULO 250 rear light 

1978 Magnum XK  candy red
9-fin, wide spoke wheels, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, ULO headlight
ULO 250 rear light, then CEV 9417 after #1500100

1978 Magnum MkII (oil injection) silver (two speed)
9-fin, “snowflake” wheels, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, ULO headlight
ULO 250 rear light, then CEV 9417 after #5195168

 

 

 

 

 

 

 

 

 

---

1979 models in Jan 1979 parts catalogs

1979 GN   red  (formerly Rigid)
7-fin. thin spoke wheels, thin ff, 2.00-17 tires
stamped-sheet “hard tail” frame, same as ’78
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches 

1979 Maxi   candy red, candy blue
7-fin, thin spoke wheels, thin ff, 2.00-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches 
same as 1978

1979 Maxi Luxe emerald green, silver, burgundy
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black  controls, sliding-block throttle
had either Merit 342, 342 or 342A, 343A switches
same as 1978

1979 Sport   silver, pearl green
8-fin, “snowflake” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
same as 1978

1979 Newport L   white, black  
8-fin, wide sp. whls, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, same as 1978

1979 Maxi II   Inca gold (two speed)
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342, 343 rounded chrome switches
same as 1978 except some don’t have blue stripes

1979 Sport MkII  pearl green (two speed)
8-fin, “snowflake” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
same as 1978

1979 Sport MkII  silver green (two speed)
8-fin, “5-star” wheels, wide ff, 2.25-17
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 “pancake” headlight, same as 1980

1979 Magnum XK  candy red, same as 1978
9-fin, wide spoke wheels, wide fenders, 2.50-17 tires
ULO 250 rear light, then CEV 9417 after #1500100
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches

1979 Magnum MkII (oil injection) silver (2 speed)
9-fin, “snowflake” wheels, wide fenders, 2.50-17 tires
ULO 250 rear light, then CEV 9417 after #5195168
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches

1979 Magnum X (off road mini)  white
9-fin cylinder, kick-start (no pedals), spoke wheels
off road tires: 2.50-14 front, 2.75/3.00-12 rear
no lights, no switches except engine stop button
Magura black controls, off-road wrap-around throttle

 

 

 

 

---

1980 models in Jan 1980 parts catalogs

1980 Maxi      candy red, candy blue  
7-fin, wide spoke wheels, thin ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 1211 “pancake” headlight

1980 Maxi Luxe  silver, burgundy, Inca gold  
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV “pancake” headlight

1980 Newport II  carmine red (two speed)
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 “pancake” headlight

1980 Sport MkII  silver green (two speed)
8-fin, “5-star” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 “pancake” headlight

1980 Magnum II   silver  (two speed)
9-fin, wide spoke whls, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO headlight

1980 Magnum MkII mocha brown, black (2 sp)
9-fin, “5 star” wheels, wide fenders, 2.50-17 tires
cockpit dash with main key, turn signal ready (some)
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, Niox/ULO headlight

1980 Magnum MkII with turn signals option
9-fin, only some had rear racks with turn signal mounts.
These ULO turn lights broke easily so most have been
removed or replaced with modern aftermarket turn lights.
.

1980 Magnum MkII restored by Bill Small 
The rear rack has no turn light mounts. only some did.
The rest of the bike is ready for the turn light kit.
The kit had 4 lights, mount bars, 6 volt Ni-Cd battery,
flasher, and hardware.

1980 Magnum X (off road mini)  white
9-fin cylinder, kick-start (no pedals), spoke wheels
off road tires: 2.50-14 front, 2.75/3.00-12 rear
no lights, no switches, same as 1979
Magura black controls, off-road wrap-around throttle

 

 

 

 

 

 

 

 

 

 

1980 carry overs: In 1980 there were 2 or 3 years worth of mopeds produced. They were stockpiled and sold in 1981, 82 and 83. This was not just Puch, it was many manufacturers. It was a way to avoid the new worldwide motor vehicle standards and labeling requirements. Motor vehicles made before 1981 were not required to have the modern 17-digit VIN with assigned manufacturer codes. And there were other safety and standardization requirements for motor vehicle manufacturers.

That is why there are 1980 models in the 1981 and 1982 line ups!

 

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1981 models in Apr ’81 and Jan ’80 catalogs

1981 Series B (made in USA by Murray) burgundy
7-fin, wide spoke wheels, Murray fenders, 2.25-17 tires
Magura black controls, sliding-block throttle
CEV 8188, 8189 switches, Niox/ULO headlight
same as Murray 8315/8320 except headlight and tank

1981 Maxi      candy red, candy blue  
7-fin, wide spoke wheels, thin ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 1211 headlight, same as 1980

1981 Maxi Luxe  silver, burgundy, gold  
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 headlight, same as 1980

1981 Newport II  carmine red (two speed)
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 headlight, same as 1980

1981 Sport MkII  silver green (two speed)
8-fin, “5-star” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 headlight, same as 1980

1981 Magnum II   silver  (two speed)
9-fin, wide spoke whls, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO headlight, same as 1980

1981 Magnum MkII mocha brown, black (2 sp)
9-fin, “5 star” wheels, wide fenders, 2.50-17 tires
cockpit dash with main key, turn signal ready (some)
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, Niox/ULO headlight

1981 Magnum LTD  midnight gold/red (2 speed)
9-fin, “5-star” wheels, wide fenders, 2.50-17 tires
cockpit dash with main key, ULO turn signals
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, Niox/ULO headlight

 

Not long after Hans Renold invented the roller chain in 1880, Johann Puch invented the safety bicycle in 1880. A year later Puch and two business partners started Styria Fahrradwerke, making safety bicycles that were chain driven, allowing the rider to sit closer to the ground. Traditional bicycles at the time were the direct drive big wheel type. Those were more dangerous and difficult to ride. The 1981 Magnum Limited commemorates the centenial anniversary of Styria, later known as Steyr Daimler Puch after merging with Austro-Daimler in 1928, and Steyr-Werke AG in 1934.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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1982 models in Apr ’81 and Jan ’80 catalogs

1982 Series B (made in USA by Murray) burgundy
7-fin, wide spoke wheels, Murray fenders, 2.25-17 tires
Magura black controls, sliding-block throttle
CEV 8188, 8189 plastic slide switches
Niox/ULO headlight, same as 1981

1982 Maxi      candy red, candy blue  
7-fin, wide spoke wheels, thin ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342, 343 rounded chrome switches
CEV 1211 headlight, same as 1980

1982 Maxi Luxe  silver
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
CEV 1211 headlight, same as 1980

1982 Magnum LTD  midnight gold/red (2 speed)
9-fin, “5-star” wheels, wide fenders, 2.50-17 tires
cockpit dash with main key, ULO turn signals
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, Niox/ULO headlight
same as 1981

 

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1983 models in Jan 1984 parts catalogs

1983 Dart  red  (outside US it’s Mini Maxi)
Dart engine, spoke wheels, 2.50-14 tires
Magura black controls, sliding-block throttle
Merit 342, 343 rounded chrome switches
Niox/ULO rectangular headlight

1983 Maxi  burgundy
7-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura silver controls, wrap-around throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight

1983 Maxi Sport LS  silver blue
7-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight, Long Seat

 

 

---

1984 models in Jan 1984 parts catalogs

1984 Dart  red  (outside US aka Mini Maxi)
Dart engine, spoke wheels, 2.50-14 tires
Magura black controls, sliding-block throttle
Merit 342, 343 rounded chrome switches
Niox/ULO rectangular headlight

1984 Maxi Sport LS  burgundy
7-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight, Long Seat

1984 Cobra  candy red
8-fin, wide spoke wheels, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight

1984 Austro-Daimler (aka Maxi Plus) silver
AD, “5 star 16” wheels, wide fenders, 2.50-16 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight

1984 JMX (off road mini) white/blue/red
9-fin cylinder, kick-start (no pedals), spoke wheels
off road tires: 2.50-14 front, 2.75/3.00-12 rear
no lights, no switches except engine stop button
Magura black controls, off-road wrap-around throttle

 

 

 

 

 

 

---

1985 models in Jan ’85 and Jan ’84 catalogs

1985 Maxi   candy red, candy blue, silver  
8-fin, thin front fender, thin front rim, wide rear
2.00-17 front tire, 2.25-17 rear tire
Magura black controls, sliding-block throttle
Merit 342, 343 switches, Niox/ULO rectangular hl

1985 Maxi Sport LS  burgundy
7-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A switches, Long Seat
Niox/ULO round headlight, same as 1984

1985 Maxi Sport LS 2  black (two speed)
8-fin, “5 star” wheels, wide front ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight, Long Seat 2-speed

1985 Cobra  candy red, white
8-fin, wide spoke wheels, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO round headlight, same as 1984

1985 Austro-Daimler 2  silver (two speed)
AD, “5 star 16” wheels, wide fenders, 2.50-16 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight

1985 Rough Rider (kids off road) white/blue/red
9-fin cylinder, kick-start (no pedals), spoke wheels
off road tires: 2.50-14 front, 2.75/3.00-12 rear
no lights, no switches except engine stop button
Magura black controls, off-road wrap-around throttle

 

 

 

---

1986 models in Jan ’86 and Jan ’85 catalogs

1986 Maxi   candy red, silver
8-fin, thin front fender, thin front rim, wide rear
2.00-17 front tire, 2.25-17 rear tire
Magura black controls, sliding-block throttle
Merit 342, 343 switches, Niox/ULO round headlight

1986 Maxi Sport LS  silver, white
8-fin, wide spoke wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight

1986 Maxi Sport LS 2  black (two speed)
8-fin, “5 star” wheels, wide ff, 2.25-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight

1986 Cobra 2  white/blue (two speed)
8-fin, “5 star” wheels, wide fenders, 2.50-17 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight, same as 1985

1986 Austro-Daimler 2  silver (two speed)
AD engine, “5 star 16” wheels, 2.50-16 tires
Magura black controls, sliding-block throttle
Merit 342A, 343A square black switches
Niox/ULO rectangular headlight, same as 1985

 

 

 

 

 

 

 

 

 

 

 

Contents:
1. M56 Versions
2. M56 Parts
3. M56 Parts Info
4. M56 Tools

 

 

 

---

1. M56 Versions

Three power and speed versions were made for Batavus USA models. 1.0 horsepower, 1.5 and 2.0. Each USA state required a different version.

Only four things are different between the speed versions. Everything else is the same.

 1.0 hp 00 1.5 hp 00 2.0 hp
20 mph    25 mph    30 mph    ##  parts that are different
———————————————————————————
560194    560180    560180 #189  crankcase 40km or 50km
540681    540681    540695 00#6  cyl. head lo or hi comp
560194    560180    560180 00#7  cylinder 40km or 50km
561787    561782    561782 #116  carburetor H9 or H12

 

 

---

1. Parts for Laura M56 Engine

The parts list below is made from the Batavus USA Spare Parts Catalog for 1978-80 Regency VA and Regency HS (20, 25, 30 mph). Combined with that are parts from the Trac USA Parts List for 1982-86 Clipper, Eagle and Hawk (25 and 30 mph).

In 1978-80 the M56 engine was made by Laura in Holland, mostly for Batavus mopeds. It was remade in 1982-85 by Daelim in Korea, mostly for Trac mopeds. The Trac remake is 90% the same. Only some pulley, pedal and drive shaft parts are different, shown below in a lighter color shade.

Price color: new  used   Part color: 25,30mph  20mph

 #  Batavus  Trac xx Price (each)
 xx  number  no.  qty xxx  Description
===============================
001 827600 04060 4 $0.30 nut M6
002 846600 06060 4 $0.25 lock washer M6
003 847600 05060 4 $0.20 washer M6
004 829682 10025 4 $4.50 cylinder stud M6x107
005 481883 80015 1 $5.00 spark plug NGK BR6HS
006 540681 00000 1 none  cylinder head (20 mph)
006 540681 80001 1 none  cylinder head (25 mph)
006 540695 80010 1 $40.0 cylinder head (30 mph)
007 560688 00000 1 none  cylinder 25km (20 mph)
007 540680 80003 1 none  cylinder 50km (25 mph)
007 560685 80003 1 none  cylinder 50km (30 mph)
008 490682 80029 1 $6.00 cylinder base gasket
009 540580 80016 1 none  piston Ø39.96 18-12-14
009 540580 80017 1 none  piston Ø39.97 18-12-14
009 540580 80018 1 none  piston Ø39.98 18-12-14
009 540580 80019 1 none  piston Ø39.99 18-12-14
009 540580 80020 1 none  piston Ø40.00 18-12-14
009 540580 80020 1 none  see pistons for substitutes 
010 561895 82013 1 $3.00 plug wire rubber boot
011 480502 80021 2 $10.0 piston ring Ø40 x 1.5 FG
012 480501 80022 1 $10.0 piston pin Ø12.0 x 33
013 841520 80023 2 $1.50 piston pin clip Ø12
014 480325 80024 1 $10.0 piston bushing Ø11.8 x 14 x 11
015 560381 80025 1 $100  crankshaft good-used or $150 new
016 810080 10034 2 $10.0 bearing 6202 C3
017 830000 80026 1 $1.50 clutch hub key 3 x 5 M-86
018 830001 80027 1 $2.00 flywheel key 2 x 3.7 M-81
019 540882 81001 1 20-30 clutch saucer
020 560395 81002 1 $1.00 wave washer 15x24x1
021 490390 81003 1 $7-11 disk nut M15-1.0
022 540886 81004 1 25-40 weight-spring
023 540803 81005 1 15-25 clutch hub
024 540898 81006 1 $15.0 metal plate
025 480889 81007 1 $19.0 friction plate
026 540899 81008 1 $5-8  star spring
027 480890 81009 1 7 –12 outer locking plate
028 820509 81010 6 $0.50 hex bolt M5x20
029 540809 81011 1 $25.0 friction lining ring, this can reduce slipping
030 560890 810??  1 50-80 clutch housing
031 813090 81013 2 $10.0 bearing 12x18x10 HK1210 or $13 for 12x18x20 HK1220
032 490813 00000 * none  shim as needed 12x24x0.8
032 490814 81014 1 $4.00  shim as needed 12x24x0.5 same as M48 one 480899
033 841505 81015 1 $1.00 circlip Ø10.9 12.0 shaft
034 560892 81016 1 none  start plate
035 480892 81018 1 $8.00 leaf spring
036 829605 80047 1 $5.00 starter stud M6 x 55
037 490293 81019 1 none  cover support plate
038 561096 00000 1 $15.0 sprocket 13T (20 mph)
038 561097 81037 1 $15.0 sprocket 17T (25 & 30)
039 490886 81020 1 $6.00 starter mount spring
040 490980 81021 1 $12.0 starter arm lever
041 827610 04060 2 $0.30 nut for starter M6
042 836103 81012 3 none  rivet for lining ring 3×6
043 843500 06050 6 $1.00 wave washer M5 thin
044 490835 none   1 $6.00 starter cable spring
045 813088 81028 1 $15.0 needle bearing 12x15x10 inner, 1 end open BK1210
046 560883 81023 1 $20.0 clutch hub Ø21 at seal
047 561385 00000 1 none  pulley shaft Batavus Ø15
T47 000000 81030 1 $45.0 pulley shaft Trac Ø12
048 561590 00000 1 $57.0 62T pulley Ø15 center
T48 000000 81026 1 $40.0 62T pulley Ø12 center
049 830004 81031 1 $3.00 shaft key 3 x 6.5 M-88
050 560891 81025 1 none  toothed belt T5x395-20, 79 teeth note 1
050 560891 81025 1 none  toothed belt T5x390-20, 78 teeth note 1
051 810182 10028 1 $8.00 bearing 17x40x12 6203
052 490813 81029 2 $4.00 pulley shaft shim 12x24x 0.8 same as M48 one 480899a
054 840011 81038 1 $5.00 tab washer Ø17 x 32
055 828200 81039 1 none  sprocket nut M12-1.25
056 561098 00000 1 none  drive shaft Batavus
T56 000000 81033 1 none  drive shaft Trac
057 541685 80030 1 $15.0 exhaust clamp
058 846600 06060 1 $0.20 lock washer M6
059 820635 25614 1 $0.40 hex bolt M6x25
063 491088 00000 1 $5.00 shim washer 10 x 24 x 0.8
T63 000000 81034 1 none  shim washer 17 x 24 x 0.8
T63 491088 81034 1 $5.00 substitute 17 x 24 x 1.0
065 561082 00000 1 none  ratchet wheel M20-1.0
T65 000000 81036 1 $45.0 ratchet wheel M20-1.0
067 491086 81035 1 $8.00 shim 20 x 31
069 816282 81044 1 $15.0 drive shaft R seal 20x26x4
070 491087 81041 1 none  plate
071 561092 81040 1 none  pedal sprocket 12T M20-1.0
075 561789 80031 1 $7.00 air box front bracket
076 490181 80032 1 $7.00 case gasket
077 490189 80033 2 $5.00 centering bush Ø8×12
078 490186 10017 1 $5.00 oil fill and check plug
079 560185 80034 1 none  grommet for magneto wires
080 823505 80048 8 $1.00 case screw slot M5x35
081 816187 81042 1 $9.00 left crank seal 15x32x7
082 816384 81043 1 $8.00 right crank seal 21x32x7
083 816186 81045 1 $6.00 pulley shaft seal 15x30x5
084 816284 81046 1 $8.00 drive shaft L seal 17x35x7
085 820675 80045 1 $1.00 carb hex bolt M6 x 75
086 829606 80047 1 $6.00 carb stud  M6 x 50
087 481784 80035 1 $4.00 reed valve gasket square
088 481783 80036 1 $49.0 reed valve 4-petal
089 829510 80046 1 $6.00 R cover stud M5 x 75
090 820501 00512 1 $0.40 hex bolt M5 x 12
091 847520 05050 1 $0.20 plain washer M5
092 560292 80037 1 $7.00 left cover bracket
093 561885 82000 1 $210  magneto good-used 0212-010-004
095 481890 82015 1 $6.00 spark plug cap
116 561782 82500 1 $220  carburetor H12 (25,30)
116 561787 00000 1 none  carburetor H8 (20 mph)
140 491797 82522 1 $6.00 gasket round
141 491796 82523 1 $23.0 insulator block (not shown)
141 491797 82522 1 $6.00 gasket round (not shown)
142 491795 80038 1 $1.00 fiber washer M6
143 843600 05060 1 $0.20 plain washer M6
148 560213 80042 1 25-40 left cover (magneto)
149 560210 80041 1 none  right cover (clutch) used
150 560291 80044 1 $12.0 slot step-cap nut rear M5
151 560290 80043 2 $12.0 slot step-cap nut front M6
153 823435 80049 2 $1.00 pan phillips screw M4x35
154 491387 00000 1 $13.0 stepped ring 15 x 24 x 4.6
155 491386 00000 1 $2.00 wire clip Ø15 shaft x 1
156 848015 00000 1 $2.00 washer 15.3 x 27.7 x 2.4
157 848012 05100 1 $0.50 washer M10
158 847000 06100 1 $0.50 lock washer M10
159 828000 81027 1 $2.00 nut M10-1.0
165 561388 00000 1 $7.00 washer 15.5×23.8×1.0
T165 00000 81032 1 none  saucer spring 12.2×22.8×1
T165 00000 81032 1 $7.00 substitute 12.2×24.8×0.9
166 823512 80050 1 $0.70 wide pan slot screw M5x12
169 540692 80028 1 $9.00 head gasket
175 561788 00000 1 $9.00 air filter bracket Batavus
175 000000 80039 1 $9.00 bracket Trac w/threads for #C
189 560194 00000 1 none  L & R engine case (20 mph)
189 560180 80040 1 $55.0 L & R engine case (25, 30)
194 820308 81017 2 $1.00 phillips screw M3x10
195 810080 10034 1 $10.0 bearing 15x35x11 6202
000  45.228 84047 1 $7.00 starter chain 3/8 x 5/32 x 32L
000 not quite #35. 35 fits, but can lift off the sprocket 
000  45.234 00000 1 $3.00 starter chain master link #35

x.
Reed valve gaskets

 

 

 

Note 1: The original belt T5X395 with 79 teeth was unavailable for many years from about 1990 to 2020. During that time the only belt available was one tooth (5 mm) shorter T5X390, sold online by Get-to-It Sales. The shorter belt was too tight unless the rear pulley teeth were shaved down. Many M56 rear pulleys have had their teeth shaved. With shaved teeth the shorter belt fits but the original belt is too loose.

To get a correct fitting belt, here is how to tell if the tops of the teeth have been shaved off. Original uses T5X395. Shaved uses T5X390. This is important because there is no way to adjust the belt tension, and no automatic belt tensioner.

 

 

 

 

---

2. M56 Parts Information

More to come…

 

---

3. M56 Tools

More to come…

 

 

Contents:
1. M48 Versions
2. M48 Parts
3. M48 Parts Info

 

 

---

 

1. Laura M48 Versions

1972 versions kmh (XX)  1976 USA 00 mph  1978 USA
M48-01  40 kmh (XX)  M48-01  25 mph    M48-11B  25 mph
M48-02  50 kmh (XX)  M48-02  30 mph    M48-02    30 mph
M48-03  30 kmh (CH)  M48-03  20 mph    M48-13B  20 mph
M48-04  30 kmh (DK) (S)
M48-05  25 kmh
M48-08  45 kmh

 

 

 

 

---

2. Parts for Laura M48 Engine

The parts list below is made from all three versions (20, 25, 30 mph) of the Batavus USA Spare Parts Catalogs shown at right, for models 1976-80 VA, HS50, Mo-bat, Bronco, Starflite VA I, Starflite VA II, Starflite HS.

1970’s USA Batavus dealers were given parts books only for their state’s speed version, and not other state’s. So a dealer in 25mph state like Arizona did not know, and could not easily find out, what parts were different in a 30mph state like California. There were just a few pages that were different.

Price color: new  used   Part color: 25,30mph  20mph

 

#   part# qty price  description

1.  480201 2 none  Batavus decal
2.  480200 2 $19.0 replacement cover
2.  480200 2 $00.0 includes 2 tabs
3.  540292 4 $3.50 cover tab (rubber)
4.  820502 2  hex bolt M5x15
5.  843500 4 $0.10 lock washer M5
6.  480981 1 $16.0 support plate
7.  480980 1 $28.0 start lever
8.  827500 6 $0.40 hex nut M5
9.  843500 6 $1.00 wave washer M5
10 480890 1 $12.0 locking plate
11 480882 1 60-25 end plate w/button
12 480824 1 none  start button
13 480883 1 $8.00 start spring ∅34 x 20 x 2.0
14 480889 1 $19.0 friction plate
15 480683 1 none  exhaust gasket
16 828010 1 $4.00 clutch nut M10-1.0×6
17 840010 1 $9.00 tab washer M10
18 480886 1 $30,0 weight-spring ring
19 810081 2 $10.0 ball bearing 6302 15x35x11
20 820520 6 $5.00 splined bolt M5x27
21 480881 1 none  alum. hub with steel saucer
21a 00000 1 $45.0 aluminum hub only
21b 00000 1 $35.0 steel saucer only
22 480887 1 $8.00 saucer spring  12x28x1.0
23 816180 1 none  felt oil ring 15x21x3
    substitute $6.00 oil seal 15x21x3
24 813081 1 $13.0 needle bearing 15x21x22
25 816480 1 none   left crank seal 20x42x7 offset
26 841512 1 $8.00 crank circlip Ø42×1.75 inner
27 838045 2 none  dowel roll pin Ø5×12
28 480181 1 $6.00 case gasket
29 480381 1 $90.0 crankshaft
30 480325 1 $10.0 piston bushing Ø11.8 x 14 x 11
31 841520 2 $1.50 piston pin clip Ø12
32 480501 1 $10.0 piston pin Ø12 x 33
33 480580 1 $60.0 piston assy Ø40×18-12-14
34 480502 2 $10.0 piston ring Ø40 x 1.5 FG
35 480682 1 $6.00 base gasket
36 829680 4 $14.0 cylinder stud M6 x 115
37 847600 4 $0.20 plain washer M6
38 846600 4 $0.20 lock washer M6
39 827600 4 $0.50 hex nut M6 x 6
40 481890 1 $6.00 spark plug cap NGK black
41 480814 1 $8.00 clutch washer 15x28x0.5
42 830000 1 $1.50 flywheel key 3 x 5mm
43 848011 1 $0.20 plain washer M10
44 828000 1 $0.50 tooth washer M10
45 828000 1 $2.00 nut M10-1.0×10
46 816181 1 $12.0 oil seal 14x30x7
    substitute $7.00 oil seal 15x30x7
47 823506 6 $0.80 case screw M6 x 25?
51 820603 2 $0.50 hex bolt M6x20
52 843600 2 $0.30 thin washer M6
53 481784 2 $4.00 inlet gasket
54 481783 1 $49.0 reed valve 4-petal
55 813086 2 $9.00 needle bearing 16x22x12
56 481591 1 $9-$6 dust cover 16.5-28.5 x 3.7
58 481786 1 $0.00 dirt splash shield
59 481797 2 $0.00 step washer M5
60 820500 2 1- .50 hex bolt M5 x 12
61 480892 1 $8.00 clutch leaf spring
63 540898 1 $15.0 steel plate
64 485194 1 none  crankcase (20mph)
64 485180 1 $0.00 crankcase (25 & 30)
65 480695 1 none  cylinder head (20 & 25)
65 485695 1 $0.00 cylinder head (30mph)
66 485697 1 none  cylinder (20mph)
66 485690 1 $0.00 cylinder (25 & 30)
67 481883 1 $5.00 spark plug NGK BR5HS
70 480185 1 $0.00 grommet for wires
71 480894 1 none  pulley-housing-thin (20)
71 480880 1 $140  pulley-housing (25 & 30)
72 486795 1 none  carb. assy 8mm (20mph)
72 481790 1 none  carb assy 8mm (25mph)
72 541780 1 none  carb assy 12mm (30mph)
73 481794 1 none  intake pipe (20mph) Ø6
73 481785 1 $25.0 intake pipe (25 & 30) Ø11
74 481594 1 none  pulley with 11T (20mph)
74 481598 1 $70.0 pulley with 13T (25 & 30)
75 480893 1 none  v-belt thin long(20mph)
75 480891 1 $23.0 v-belt thick (25 & 30) Gates XL-9319
76 481091 1 none  sprocket 11T (20mph)
76 481093 1 28-18 sprocket 13T ∅28.5 2-flats (25 & 30)
77 481506 1 none  tab nut (20mph)
77 481505 1 $18.0 tab nut M27-1.0 x 4 (25 & 30)
79 480899 1 $8.00 clutch washer (25,30) 12x24x0.5
00 480899a  $5.00 clutch washer thicker 12x24x0.8

 

---

3. M48 Engine Parts Information

Small clutch parts: Most of the small clutch parts are in this photo.

Top row, #17 840010 tab washer, #4 820502 hex bolt, #5 843500 washer, #6 480981 plate, #61 480892 leaf spring, #22 480887 saucer spring (used), #20 820520 splined bolt.

Bottom row, #24 813081 needle bearing, #23 816180 felt ring, #41 490814 washer, #22 480887 saucer spring, #79 480899 washer.

Saucer spring: You can see the shiny rings on the used saucer spring. They are where the contact was. The dark areas never touch anything. 

Leaf spring: The leaf spring goes on any one of the ten tabs of the friction plate, under the basket. What it does is reduce vibration. It stops the jingle bells sound, and helps the friction plate tabs last longer. It is not essential, but very beneficial. 

Crank Seals: Laura M48 uses crank seals that are 1 mm smaller (tighter) than normal.  The 15mm right side has a 14x30x7 seal. The 21mm needle bearing case on the left side has a 20x42x7 special seal with an offset lip. 

Friction Plate #480889: 10 tabs, each 10.5mm wide, inner diameter 58.5mm, outer diameter 92.4mm (100.4mm at tabs), thickness 3.65mm.

Note: The tabs break off when the slots in the basket become worn or notched on one side. This is because not all ten tabs are sharing the load evenly. A worn clutch housing/basket also makes the clutch stick and not go into “neutral”.  

Pulley-Housing #480880: 10 tabs, 10.3mm wide, ID 94.0mm, OD 98.6mm, center needle bearing ID 15.0mm, OD 21.0mm, length 22.0. Comes with the needle bearing only. Price $150 new, $100 almost new not worn. Far left, a new one and a worn out one. The slots for the tabs get worn wider where the plate tabs push at. Filing those flat will help, but it might still stick sometimes.

 

Pulley-Housings: 480880 (painted red) has a wide pulley for US 25, 30 mph and Euro 40, 45, 50 kmh versions. 480894 (painted yellow) has a thin pulley for US 20 mph and Euro 25, 30 kmh versions. 480880 red is deeper (25.5 mm) than 480894 (24.4mm).

 

 

 

 

 

 

 

 

 

 

Clutch Washers: The Batavus crank goes from 12mm to 15mm right at the edge of the needle bearing. The clutch needle bearing is lubed by the gasoline and oil mist in the crankcase. The three special steel washers, one cupped, seal the crankcase pressure on the spinning crankshaft, along with the rubber crank seals.

 

First the felt ring #23 goes into a recess in the housing-pulley #71. Then the large 15mm washer #41 goes on, just over the 12-15 step in the crankshaft. Then the 12mm saucer spring #22 goes on with the dish side up (outward). Then on 25 and 30 mph versions with the brick red pulley, the 12mm small washer #79 goes on, into the dish of the saucer spring. Then the aluminum clutch hub with large steel saucer in back goes onto the flat sided part of the crank, and rests against the #41. When the outer nut is tightened, the saucer spring is compressed slightly, so that the crankcase is sealed by the metal-to-metal contact ring between #79 and #22. When the engine is running, but the rear wheel is stopped, #79 spins, but #41 is stationary. Once the bike gets over 10mph, #41 and #79 are both spinning in sync, so the metal-to-metal pressure seal gets better.

 

Crankcase Pressure Leaks: All of this special washer business allows the needle bearing to never need greasing. But if a washer is missing, there is a small pressure leak. A small crankcase pressure leak causes a small loss of engine power at low speeds.

On a two-stroke crankcase the leak alternates in both directions. Piston going down causes some fuel mist to get pushed out. Piston going up causes some fresh air to get sucked in. Then the cycle repeats. Because of the rapid reversal of direction, at low engine speeds the leak has more time to happen, due to inertia. So the effect of leaving out one of the washers is to cause less “low-end torque”. The engine is weak until it gets going fast, then it is normal but lean.  

There is a small grease seal in the needle bearing #24. But it is not a pressure seal with a ring spring. So it is sealed partially, even without the washers. That is why leaving out the washers only causes a small loss of low speed power.

Left Crank Seal: The clutch side crank seal is special. The lip lies outside of the edge plane. That is to say, it sticks out. On most other seals the seal lip lies in between the edge’s planes.

A regular seal lip is in the wrong location. It cannot hug the needle bearing shell.

 

 

Engine Covers:

Laura M48 magneto (right) and clutch (left) covers are the same. There are different versions, including aftermarket, and different stickers.

Motobecane, Laura Batavus, Laura Badger, TYM Angel, TYM Speed Bird magneto covers all interchange, because they all have a 124 mm inner diameter. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

This is an aftermarket 124mm ID engine cover for an ’80’s Motobecane. You can see it looks slightly different but fits Batavus. Price $18 with two rubber fastener tabs.