MOTOR TYP 502 Engine Type 502 125 cc TECHNISCHE DATEN MOTOR MOTOR: 125. v0 BAUART HUBRAUM Fiuessigheitegekuehiter Einzyiinder-Zweltakt-Ottomator Mx: 27,2 KW (97 PS) Enduro: 28,5 kW (36 PS) NENNOREHZAHL KRAFTSTOFE. ‘MISCHUNGS- VERHALTNIS 11500/min 11250/min 1:40 Bel Verwendung Von Hochwertigen Zweltaktoein. (mm Zweifelatall Setzen Sie Sich Bitte Mit Ihram importeur in Verbindung Oder Mischen Sie Vorsichtshalber 1:20. @_ MASS “x (0,55 ~ 0,65 mm ZUENDZEITPUNKT v.OT MX: 1,5mm (17,39 Enduro: 1.4 1,8mm (18.7 - 17.3°) ‘ZUENDKERZE Bosch W 07 CS (W 370 S2S) ELEKTRODENABSTAND. ‘GETRIEBESCHMIERUNG. 0.6 mm 05 Liter Motor6l SAE 30 KUEHLFLUESSIGKETT ZUENDANLAGE GENERATORLEISTUNG. GENERATOR- ANSCHLUESSE TECHNICAL DATA ENGINE Design Platon dleplacement Bore/stroke. 1.1 Liter; Miechungeverhaitnis 2:1 = Frostechutzmittel: Wasser Kontaktios Gesteuerte Thyristor-Zuendaniage Enduro: 8V 35/5/21 W MX: kein Generator Gelb 35W, Weiss SW, Grun 21 Liguid-cooled single-cylinder two-stroke engine 124.8 cc 84.25/54 mm Performance max. MX: 27.2 KW (97 HP) Enduro: 26.6 KW (36 HP) rpm at max. HP 11800 11250 Fuel ‘Super fuel, research octane no 98, mixed with two-stroke ol ‘Oll/gasotine ratio 1:40 when using high-grade two-stroke competition oll, When in doubt, please contact your Importer or use 1:30 mix ratio to be on the sate side. "> _Dimension =X" 055-065 mm Ignition timing BTDC Spark Plug Electrode gap ‘Gear kibrication MX: 1,5 mm (17,39) Enduro: 1.41.5 mm (18.7 - 17.3") Bosch W 07 6S (W 470 S28) O68 mm Ors live engine oll SAE 30 Coolant 1.1 Wtres mixture 2:1 of anti-freeze and water Tonition system ‘Solid-state thyristor ignition eyatem ‘Generator output Generator connections Enduro: 6V 86/8/21 W MX: no generator yellow 35W, white 6W, ‘green 210 Caer) Tr UM NACH DEM WIEDERMON- TIEREN DES ZYLINDERS DIE AICHTIGE EINSTELLUNG ZU ERHALTEN, IST FOLGENDES MASS *X* EINZUHALTEN (UNTERLEGEN VER- SCHIEDEN STARKER ZYLIN- DER-FUSSDICHTUNGEN) BEIM MESSEN IST OER ZYLINDER NIEDERZUSPAN- NEN UND DER KOLBEN AUF DEN OBEREN TOT-PUNKT 2U STELLEN. DAS TIEFENMASS DER. ‘SCHIEBE-LEHRE SOLL 1,0 - 1,2 mm DICK SEIN. In ordar to ensure a correct fit when the cylinder Is re: sembied, the dimension ‘must be maintained by using different thicknesses for the eylinder bottom gasket. When measuring “X", the cyl. Inder should be clamped down and the piston adjusted to the ‘TDC position. The caliper shaft should have fa thickness of 1.0 to 1.2 mm.GETRIEBEVEBERSETZUNGEN PRIMAER- UEBERSETZUNG| GETRIEBE. UBERSETZUNG ORIGINAL UEBERSETZUNG HINTERRAD felt) Transmission MX. Enduro 19:92 18:90 1 14:23 18:21 21:25 20:21 VERGASER-GRUNDEINSTELLUNG E-GS 12:34 Mx 13:60 Enduro 13:48 19:45 MX EXC. MX Enduro 19:32 12:34 18:30 18:31 14:23 14:23 16:21 18:21 21:25 21:25 20:21 20:20 tet gear 2nd gear 3rd gear 4th gear Sth gear 6th gear 13:48, 13:45, Enduro BASIC CARBURETTOR SETTING \VERGASERTYPE, HAUPTOUESE DELL'ORTO. PHSB 38 MS. DELLORTO, VHSB 37 FD 212 ‘carburettor type main jet NADELOVESE 264 DP. needie jet LEERLAUFDUESE 40, iting jot DUESENNADEL, K55 Jot needie NADELPOSITION (VON OBEN) 2 ‘needle position (trom top) GEMISCHREG. SCHRAUBE OFFEN ‘SCHIEBER 1,5_Umdr./turn 40 mixture adjustment screw open throttle valve ‘STARTDUESE TOLERANZEN - EINBAUSPIEL KOLBENEINBAUSPIEL, KOLBENRING-STOSSPIEL PLEUELLAGER - RADIAL (GETRIEBEWELLEN - AXIALSPIEL, KUPPLUNGSDRUCKFEDERN - LAENGE DICHTUNGSSTAERKEN MOTORGEHAEUSE, 70 ‘starting jet TOLERANCES AND FITTING CLEARANCES 0,1 0.3 mm (0,015 ~ 0,025 mm 0.1 - 0,2 mm D2tmm_1-somm 0.3 mm _plston fitting clearance piston ring end gap, ‘connecting rod bearing ~ radial ck tranemission shaft end float clutch springs ~ length THICKNESSES corank KUPPLUNGSDECKEL ‘ZUENDUNGSDECKEL 0.3 mm 0.5 mm ‘clutch cover Ignition cover WASSERPUMPENDECKEL 0.8 mm water pump cover ZYLINDERFUSSDICHTUNG NACH BEDARF/as required (0,05/0,1/0,15/0,3/0,5/0,75 mm) cylinder bottom gasket ZYLINDERKOPFDICHTUNG ANZUGSDREHMOMENTI BUNDMUTTEAN ~ ZYLINDERFUSS. ‘O-RING 2 x 60 m7 29 Nm (3 kp) ‘oyinder head MCRL NC MO ae es) nuts ~ eylinder bi ZYLINDERKOPFSCHRAUBEN BUNOMUTTER-SCHWUNG (UINKSGEWINDE) M7. 18 Nev (1.8 kom) Mizxt | 54-59Nm (5.5 - 8 kom) ‘eylinder head bolts flywheel collar nut (LH thread) MUTTER FUER PRIMAERRAD 68 ~ 03. Nm (9 - 9.5 kom) Mi46x 1.5 nut for primary sprocket MUTTER FUER KUPPLUNGSMITNEHMER Mi6x1,8 | 88—93 Nm (9 - 9.5 kom) rut for Inner clutch hub MOTORGEHAEUSE- UND DECKELSCHRAUBEN 8.Nm (0,8 kpm) crankcase and cover boltsAa NELIEILE SUPINE FARIS MOTORGEHAUSE / ENGINE CASE iy Tellerummer She BS Tadenurmer ‘sk fa Patna oy Pe Yann oy 1 89-502.301 502.90.000.648| 1 a s0@30080000 1 = 020.000.600 1 42 580:3.005.001 043m (2 amu 560.30.027.000 1 43. §70.05.020.001 043m 510.80.026.100 1 48 90231.005.000 501.90.010.000 2 45 580.31.005.100 1 501.33.026.000 1 80 s02s005108 = 0912 060169 1 61 64230051000 1 502.34021.000 12 50290082000 2 501.30.016200 1.8mm 1 53. 542:30058.000 2 502132.050 000 15 $4290.056.000 2 0912 o60T03 2 86 0084 040083 8 502.90.039.000 1 60 802300541001 490,90.096.000 1 61 5020050000 1 380.8, 020.000 462 54390061001 580.38.022.000 163. 0137.060000 5 360.30.020.000 1 64 0963 420132 4 0770 160030 1 70. 0912060853 1 §60.32.019.000 1.71 0912060808 2 0936 080008 +72 0912 060853 2 510.30.022.000 173-0812 06080 3 310.07.007.001 0.3m 74 0812 080803, ‘ 502.30.001.100 175 0812080283 7 0826 060240 +76. 0912.080208 9 502.30.028.000 177 cetzoco16s 3 500.30.028.000 2 78 0012 060088 1 490.30.029.000 +80 548:0.060.00 420.18.228.000 +81 0812 080289 1 025,001,000 + 82 0912 060208 1 502.36.002,000 1 = s02s0.t00.00 1 580.96.065.000 1 DICHTUNGSSATZ/ 502 30,002,100 1 Gaskerser Tolenimmwe = $K_——BBS__—Telounr eK tena oy Bataan & 30290007500 1 «=» 18 60280.078.000 1 50230.082.600 1190625 082058 1 50190095.000 12040770 280012 1 seosoo7acn0 = 22 02.0.016.000 1 51090034000 1-—=—«22 0760-304 260 1 502.30.018.500 1 ~—=«-23 60080048000 90290018.5s = 120896 140155 1 0886 030050 2 80. 0626 060008 2 54390023000 181 $02.35.0100% = 1 760 254070 132 0760 102260 1 0137 120000 +33 802.98,008.000 1 510.30.028.100 1—=—=«34_0349.000050 1 0968 080088 335 912 050123 1 BILD, TEILENUMMER STK BLD. TELENUNMER STK. FIG.” PART NUMBER QTY. FIG. PART NUMBER QTY 1 502,20,006,144 1 10 $02.00.096.500 1 2 490.30.080.000 111 $02,30.005.000 1 3 0012 060288 3 12 $02.30.008.100 1 4 810,08.074.000 2 18 s80.36.088.000 1 5 502.90.090.008 0,08mm X 47 812 060083 5 502.90,090.010 0.0mm X 19 $00.0.680.000 6 5 802.00.030.018 0,18mm X 14 01260700098 5 $02,90.030.090 0,3 mm X 18 $00,00.070.000 6 § 02.20,090.050 0.5mm X 20. 544.96.097.000 1 5, 502,90,090.075 0,75 mm X 21 502.35.008.000 1 6 502.30.043.000 4 2 o1s7 0600002 7 49030.028.000 423° ostz 060203 2 8 490.30.028.000 1 24 100.01.020.000 2 9 580.26.092.010 1 25 $66.36.007.000 1 X = NACH BEDARF/ as requiredAUSLASSTEUERUNG / VALVE CONTROL, VERGASER VHSB 37 MX / CARBURETTOR ig Fo at Tolenummer Partnumber 502.31.001.644 802.31.197.037 '502.31.135,040 490.31.134.055 '502.31.521.264 '490.31.122,000 570.31.523.212 151.31.123,040 490.31.151,070 572.31.120.350 '545.31.509.000 570.31.625.100 502.31.127.000 490.31.131.000 0799 025055, 490.31.130.000 502.31.137.000 0963 045103 490.381.149.000 '490.31.108,000 490.31.108,000 491.31.513.100 490.31.212.100 BILD. TEILENUMMER STK. PART NUMBER QTY. 802.37.060.044 548.37.099.000 545.37.098.000 '545,37.097.000 0402 251380 0625 008088 '548.37.030.000 420.13.226.000 502,37.024,044 502.37.026.044 502.37, 198,055 $02.37.022.044 0912 050123, 02.37,103,000 0084 040083. 502.397.020.000 070 100020 0625 628002 '548.37.010.000 0770 180020 0988 162210 '502.37.005.000 502.37.008,000 0966 060303, 0966 060253, 502.37.007.000 '502.37.007.050 Tolenurener Par number 602.31.111,000 0127 050003 (0084 050203 490.381.112.000 502.31.114,000 545.31.74,000 502.31.136.000 570.831.515.000 490.381.117.000, '502.31.150.000 '502.81.120.000 (0966 040083 545,31.599,000 490.391.198.000 601.31.137,000 830.13.096.000Engine Type 502 VERGASER PHSB 35 ENDURO / CARBURETTOR au 5 TEILENUMMER STK. BILD, TEILENUMMER STK. FIG. PARTNUMBER QTY. FIG, PART NUMBER QTY. 1-97 502.31,501.044 23 570.1.515.000 490.31.138.000 24 490.391.108.000 490,91.134.042 26 490.91.212.100 490.91.921.270 27 0603 082121 490.31.122.000 28 491.31.519.100 $70.31.823.220 29 490.391.108.000 151.81.128.055 30 490.31.174,000 490.31.181.070 31 490,31.110.000 572.1.120.300 32 490.31.111.000 490.31,109.000 38 0127 050003, 490.91.119.100 34 0084 050203, 490.31.116.000 38 0603 182310 490.31,138.000 36 490.31.114.000 870.91.525.100 87 490,31.112.000 490.31.227.000 95 501.1.197.000 490.31.128.000 96 830.13.096.000 490.31.127.000 99 490.31.199.000 490.31.131.000 490.31.130.000 0799 025055 0963 045103 490.31.149.000 490.31.117.000 TEILENUMMER ‘TEILENUMMER PART NUMBER PART NUMBER '602.92.001.661 0471 100010 502.32.001.000 44.32.001.100 0860 050100 02.32.080.000 '501,32.010.000 0933 060203 501,32.095.000 60.32.030.062 $01.32.096.000 560.32.030.050 01.92.002,200 $02.32.015.200 01.92.018.100 02.32.095.000 0936 160155 602.32.090.000 501.92.008,100 502,32.091.000 01,32.009.100 0471 120010 '501.22.009.200 $45,32.093.000 02.2.017.000 $02.32.013.000 224 501.92.003.200 0084 040083 502.32.016,000 912 060163 X = NACH BEDARF/as requiredZUNDANLAGE / IGNITION SYSTEM BILD. TEILENUMMER STK |. TEILENUMMER STK FiG, PART NUMBER QTY. |. PART NUMBER GTY. 1A 501.91.102.200 51091.010.100 Mx 510.31.010.200 501.31 002,000 510.31.010.300 ENDURO 560,31.093.970 0085 050203, 502,31.012.000 0137 050003 0983 060163, (0125 050003 (0128 060003 510.31,004.000 0021 060003 502.31.031.100 fans coon) 490.31.031.051 870.13.070.000 $10.31.011.000 0125 050003, Si ad (0912 050103 4100.11.072.100 oss 040203 440.11.076.180 ones antes] 490.31.013.000 maar osOnS) -490.31.113.000 0126 050003 510.31.006.200 X = NACH BEDARF/as required BILD. TEILENUMMER stk. FIG. PARTNUMBER = QTY. 501,34,014.000 1 5 7 544.093.135.000 1 502.34.006,000 1 490.34.009,000 1 02,34.002.000 2 802.34,004.000 1 '502.34,001.000 1 802,34.003,000 1 846.92.095.000 1 802,34.012.500 1 501.34.028.000 1 802.34.018.000 1 0991 060203. 1 502.34,024,044 1 02,34,023.000 1 802.34.020.000 1 (0799 080000 1 1 1 90-502.34.1 0760 142460 801,34,022.000KICKSTARTER / KICKSTARTER id" Telenurmer Sk Bid —Talerurnmer Si Fg Patomber Qy Fg Partrumber ay 1 490.83.026.100 1 7 0984 060203 2 2 §02.38.020.000 + 8 502.33,023500 1 3 $02.38.022.500 + 9 49033028000 1 4 501.98.024.000 1 10 490.83.031.000 1 5 490.93.021.100 1 11 0760 142460 1 nye 6 $02.38.027.100 + 20 02.93.036.044 1 ' 21. 7mm 21 502.33.041.000 2 22 0912 060163 1 | 90-502,33.1 J X = NACH BEDARF/as required TRI TEILENUMMER STK. BILD, TEILENUMMER stk. Gi IEBE | / TRANSMISSION | PART NUMBER QTY. FIG. PART NUMBER ary. 7 502,33.007.500 212 5. 115A §01.33.018.000 1 8 502,33.008.600 14/152 3./4. 1 188 $01.99.018.100 1 9 $02,33.000.600 202 6. 1 30 $60.39.030.000 1 40 $02.98,010.500 1622. MX 1 90 501.39.090.000 2 10 502.93.110500 1522, 1 93 549.99.099.000 1 b ENDURO 95 0625 982040 1 (it Strnille/with groove) eaieniTasleos'onn a 11 902.93.011.800 192 1.MX 1 41 502.93.111.600 1221 1 ENDURO. GETRIEBE Il / TRANSMISSION II aio, TELENUMMER, STK. BILD. TEILENUMMER stk, FIG. PART NUMBER QTY. FIG. PART NUMBER ary. 01 §00.33.001.000 116A 502.83.018.000 1 502.33,001.600 9221. MX 1 17A _502.99.099.000 1 §02,93,101,600 34Z 1. 1 017 $01.39,018.000 - ENDURO 20 §60.83.020.000 2 $02.38.002.500 282 1 29 §00.33.029.013 3A $02.33.003,500 232 3. 1 30 560.98.030.000 4A 502.33.004.800 212 4. 133 $00.93.033.000 $02.33,005.500 2126.MX 1 80 0625 062058 $02.33.108.500 202 8. 11 0760 324770 Sue 82 0770 020220 6A 502.33.006.500 3022.MX 1 904 0471 250020 3 GA 502.33,108.500 3122 1 908 0471 220175 ENDURO 93 §43.33.093,000 Og "2h $02.39.012.500 TE sei seolss"aca!oon 88-502.29.3 98 500.93.098,000KUEHLSYSTEM / COOLING SYSTEM. BILD, TEILENUMMER FIG, PART NUMBER 502.35.008.000 (4.5038) 490.35.016.000 1 '$02.35.007.000 (4.5037) t 545,95. 134.000 1 548,38.034.000 1 502.38.033.000 4 0966 050203, ‘ $85.35.028.000 2 565.38.025.001 m 565.35.027.000 1 100.01.020,000 2 $44,98.024.001 m 544,36.023.100 2 '550,07.016.001 m 440.11,076.185 x 410.01.082.000 6 510.08.097.000 6 0797 060003 6 0933 060163 6 X = NACH BEDARF/as required SPEZIALWERKZEUGE / SPECIAL TOOLS Bees. TeILENUMMER PART NUMBER 60.12.001.000 601.12.001.050 01.12.008.000 502. 12.022. 100 08.12.008.014 02.12,008.000 $10.12,000.000. wa27x1 6278807 Ma6x1,6 510.12.011.000 s10.12.014.000 s10,12.016.000 11.12.017.000 181.12.018.100 02, 12.004. 000 801.12.013.000 e 501.12.080.000 a $44.12.012.000 sea 6 899 786 J LOCTITE BLAU 242/ eS ‘Saw sur 07-802. 12.1