Garelli 2V (VIP)

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[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:

1980 Garelli VIP Stock 49cc 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:

Garelli VIP 68cc Olympia Kit 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


Clutch Side

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