Garelli 2V (VIP)

[Intro]

[Overall gearing ratio to output shaft:
1st gear = 67:18 * 39:14 = 10.37:1
2nd gear = 58:27 * 39:14 = 5.98:1
Pedals = 11:17 = 0.65:1]

Rebuild Parts

• Bearings and Bushings [1]
  • Crankshaft
    • Clutch side (roller): 6203/C3 [2]
    • Magneto side (roller): 6203/C3 [3]
  • Main Shaft
    • Clutch side (roller): 6203/C3 [4]
    • Internal (needle): HK 1312 [5]
  • Drive Shaft
    • Internal (bushing): 20× 24 x 14 Brass with oiler cuts
    • Magneto side (roller): 16004 [6]
  • Pedal Shaft (none)
• Seals [7]
  • Crankshaft
    • Clutch side: 17 × 40 x 7
    • Magneto side: 17 × 40 x 7
  • Main Shaft (none)
  • Drive Shaft
    • Magneto side: 20 × 42 x 7
  • Pedal Shaft
    • Clutch side: 16 x 24 x 4
    • Magneto side: 16 x 24 x 4

[note: pedal shaft seals are difficult to find; 16x24x5 seals [8] will work.]

Combustion End

39mm Stroke

Top End

49cc Stock

Piston ported
Bore diameter = 40.xmm
Head gasket recessed into head
Threaded exhaust = 35.2mm x xxx.xxmm x xxx.xxmm long
Internal exhaust dia. = 25.2mm
Square bolt pattern = 7.2mm holes spaced at 47.6mm
Machined height (without skirt) = 61.3mm
Intake diameter = 22.6mm
Two intake bolts = xxx.xxmm x x.xxmm spaced at 40.0mm

Port Timing (assuming 2.0mm deck height):

• Exhaust
  • Height to deck: 30.2mm
  • Duration: 139 deg
• Transfer
  • Height to deck: 34.1mm
  • Duration: 110 deg
• Blowdown
  • Duration: 14.5 deg
  • Pct. of Transfer: 13.1%
• Intake
  • Height from bottom to deck: 58.2mm
  • Piston height: 46.2mm
  • Duration: 112 deg

Port Map:

68cc Olympia Kit

Piston ported
Bore diameter = 46.xmm
Compatible with stock head
Compatible with stock exhaust
Stock exhaust compatible but restricted
Head gasket recessed into head (same OD as stock, smaller ID)
Threaded exhaust = xx.xmm x xxx.xxmm x xxx.xxmm long
Internal exhaust dia. = xx.xmm
Square bolt pattern = x.xmm holes spaced at xx.xmm
Machined height (without skirt) = xx.xmm
Intake diameter = xx.xmm
Two intake bolts = xxx.xxmm x x.xxmm spaced at xx.xmm

Port Timing (assuming 0.5mm deck height):

• Exhaust
  • Height to deck: 24.9mm
  • Duration: 163 deg
• Transfer
  • Height to deck: 31.8mm
  • Duration: 117 deg
• Blowdown
  • Duration: 23.5 deg
  • Pct. of Transfer: 20.1%
• Intake
  • Height from bottom to deck: 58.2mm
  • Piston height: 41.5mm
  • Duration: 149 deg

Port Map:

70cc Polini Kit

[no info]

Bottom End

• Connecting Rod
  • Center-to-center length: 90mm (est. -- to be confirmed)
  • Small end ID: xx.xmm
  • Big end ID: xx.xmm
  • Small end OD: ~xx.xmm
  • Big end OD: ~xx.xmm
  • Overall length: xxx.xmm

Magneto Side

CEV 6939 Flywheel
6V AC system with two coils (ignition and lighting)
Spins clockwise
[Puller dimensions]

3-wire Magneto:

• Black - Ignition through switch
• Blue - Ignition ground through brake light
• Yellow - Lights coil to head, tail, speedo, horn

[note: hardwire ignition by grounding blue wire]

Stock timing: 1.9mm = 23 deg. BTDC
Stock points gap: 0.014" to 0.018"
Stock plug gap: 0.020" to 0.024"
Stock plug (30MPH): Bosch W5A, NGK B7HS, Champion L-82

Internals

Output shaft is splined; available sprockets are 10T, 13T (stock), and 17T Rear sprocket (get bolt pattern): 22T, 24T, 26T, 30T (stock), 32T, and 34T available