Maico SQUARE BARREL Manuel utilisateur

SQUARE BARREL

ENGINE SECTION

NOTE: ALL THREADS ARE RIGHT HAND

(Clockwise to tighten - counter

clockwise to loosen).

SQUARE BARREL

ENGINE SECTION

NOTE: ALL THREADS ARE RIGHT HAND

(Clockwise to tighten - counter

clockwise to loosen).

MAICO

Service Manual

Square Barrel Engine Manual Service Manual

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I. Preparation For Disassembly Of The

Engine

1. All dirt, mud, dust, and foreign

material must be thoroughly re-

moved from the exterior of the en-

gine assembly before removal and

disassembly.

II. Engine Removal And Disassemblv

Drain the transmission oil by re-

moving the drain plug located at

the underside of clutch cover just

ahead of the foot rest. The plug

has a 17 mm hex. Remove foot rests.

The transmission/Primary holds lOOOcc (1 Liter).

2. Remove carburetor - medium screw

driver.

Note: Disconnect wire to coil if motor-

cycle is equipped with external

coil. The coil is located under

the gasoline tank.

I. Preparation For Disassembly Of The

Engine

1. All dirt, mud, dust, and foreign

material must be thoroughly re-

moved from the exterior of the en-

gine assembly before removal and

disassembly.

II. Engine Removal And Disassemblv

Drain the transmission oil by re-

moving the drain plug located at

the underside of clutch cover just

ahead of the foot rest. The plug

has a 17 mm hex. Remove foot rests.

The transmission/Primary holds lOOOcc (1 Liter).

2. Remove carburetor - medium screw

driver.

Note: Disconnect wire to coil if motor-

cycle is equipped with external

coil. The coil is located under

the gasoline tank.

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Square Barrel Engine Manual Service Manual

11. Remove the ignition cover - me-

dium blade screw driver. Not

necessary for transmission re-

pair.

12. Remove the three screws holding

the magneto housing - medium

blade screw driver. Not neces-

sary for transmission repair.

13. Remove the electrical wire going

to the coil from the points and

pull through the case removing

the rubber grommet.

11. Remove the ignition cover - me-

dium blade screw driver. Not

necessary for transmission re-

pair.

12. Remove the three screws holding

the magneto housing - medium

blade screw driver. Not neces-

sary for transmission repair.

13. Remove the electrical wire going

to the coil from the points and

pull through the case removing

the rubber grommet.

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Square Barrel Engine Manual Service Manual

14. Remove the magneto rotor - small

blade screw driver, Bmm wrench,

impact slide hammer puller. We

recommend the use of a slide hammer

puller as shown.

15. Remove cylinder head - 13mm

socket.

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Square Barrel Engine Manual Service Manual

16. Remove cylinder

NOTE: To remove cylinder with engine in

the frame, remove the studs with a

small vise grip pliers. Push the

piston to SDC and remove the cylinder.

17. Remove pin clips - needle nose pliers.

Push pin through and remove piston

and bearing. Note the shop towel in

the top of cases to keep foreign

objects from falling into the lower end.

Do not reuse piston pin clips.

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Square Barrel Engine Manual Service Manual

18. Place engine in engine stand

with clutch cover up.

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Square Barrel Engine Manual Service Manual

19. Measure the piston and measure

the cylinder bore. If the cylin-

der bore is greater than .006

inch, replace the piston. It is

wise to check the cylinder bore

in at least 3 places; top, mid

and bottom to be sure that the

cylinder is round and is true

from top to bottom.

Rebore when the total deivation

in the cylinder is greater than

.006 inch from a new piston.

A new piston shall have .002 inch

clearance between piston and

cylinder wall measured at bottom

of skirt. The machine will re-

quire 75-100 miles break in prior

to racing.

20. The piston rings shall be check-

ed for end gap. A new ring has

.010 inch end gap. When end gap

exceeds

.016

inch replace piston

rin~s.

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Square Barrel Engine Manual Service Manual

21. Remove:

A. Kick starter

1. 360-250 - Remove snap ring

and loosen pinch bolt -

ice pick and l7mm wrench.

2. 400-501 - Remove 6mm bolt

10mm wrench.

B. Remove seven 6mm screws from

the cover - medium blade

screw driver.

C. Pull the cover straight up

Note: For serv1c1ng clutch with en-

gine in the frame, lay the

machine over with the right

side down. Pull the plastic

.transmission vent hose out of

the case just above the chain.

Turn the hose

180

so that

transmission oil will not run

out. Having the motorcycle

level will greatly assist

when replacing the clutch springs.

22. Remove the clutch snap rings

with special puller and two

small blade screw drivers.

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Square Barrel Engine Manual Service Manual

23. Remove

hand the clutch plates,

clutch guide, and note direction

of fiber plate and spring stack

up.

2~. Clutch spring height

new .075 - replace .070

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Square Barrel Engine Manual Service Manual

25. Clutch spring heavy 360 - 400

Place two springs face to face,

then add two more springs one

on each side, making a set of

4 springs. Use 18 springs, ma-

king 4

1/2

sets. Twenty springs

may be used -

sets - for more

spring pressure.

26. Clutch spring light 501 and

early oval barrel 250 and 360.

Take two springs face to face

for set of 2. Use 20 springs,

making 10 sets of 2 springs •

...

Late model 400 and 501

clutches that are the light

weight model uses 18 springs

stacked as shown above.

25. Clutch spring heavy 360 - 400

Place two springs face to face,

then add two more springs one

on each side, making a set of

4 springs. Use 18 springs, ma-

king 4

1/2

sets. Twenty springs

may be used -

sets - for more

spring pressure.

26. Clutch spring light 501 and

early oval barrel 250 and 360.

Take two springs face to face

for set of 2. Use 20 springs,

making 10 sets of 2 springs •

...

Late model 400 and 501

clutches that are the light

weight model uses 18 springs

stacked as shown above.

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Square Barrel Engine Manual Service Manual

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