Download
Share
Print this page
  1. Manuals
  2. Brands
  3. Maico Manuals
  4. Motorcycle
  5. SQUARE BARREL
  6. Service manual

Maico SQUARE BARREL Service Manual

Engine section
Hide thumbs

Advertisement

Quick Links

Download this manual
Service Manual
www.maicowerk.com
MAICO
SQUARE BARREL
SQUARE BARREL
ENGINE SECTION
ENGINE SECTION
NOTE:
NOTE:
ALL THREADS ARE RIGHT
ALL THREADS ARE RIGHT
(Clockwise to tighten - counter
(Clockwise to tighten - counter
clockwise
clockwise
Square Barrel Engine Manual Service Manual
HAND
HAND
to loosen).
to loosen).
Courtesy of vintagemaico@gmail.com

Advertisement

loading
Need help?

Need help?

Do you have a question about the SQUARE BARREL and is the answer not in the manual?

Questions and answers

Related Manuals for Maico SQUARE BARREL

Summary of Contents for Maico SQUARE BARREL

  • Page 1 Square Barrel Engine Manual Service Manual MAICO Service Manual SQUARE BARREL SQUARE BARREL ENGINE SECTION ENGINE SECTION NOTE: NOTE: ALL THREADS ARE RIGHT ALL THREADS ARE RIGHT HAND HAND (Clockwise to tighten - counter (Clockwise to tighten - counter clockwise clockwise to loosen).
  • Page 2 Square Barrel Engine Manual Service Manual I. Preparation I. Preparation For Disassembly For Disassembly Of The Of The Engine Engine 1. All dirt, mud, dust, and foreign 1. All dirt, mud, dust, and foreign material must be thoroughly material must be thoroughly...
  • Page 3 Square Barrel Engine Manual Service Manual 11. Remove the ignition cover - me- 11. Remove the ignition cover - me- dium blade screw driver. Not dium blade screw driver. Not necessary for transmission re- necessary for transmission re- pair. pair.
  • Page 4 Square Barrel Engine Manual Service Manual 14. Remove the magneto rotor - small blade screw driver, Bmm wrench, impact slide hammer puller. recommend the use of a slide hammer puller as shown. 15. Remove cylinder head - 13mm socket. www.maicowerk.com...
  • Page 5 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.
  • Page 6 Square Barrel Engine Manual Service Manual 18. Place engine in engine stand with clutch cover up. www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 7 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...
  • Page 8 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.
  • Page 9 Square Barrel Engine Manual Service Manual 23. Remove hand the clutch plates, clutch guide, and note direction of fiber plate and spring stack 2~. Clutch spring height new .075 - replace .070 www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 10 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 25. Clutch spring heavy 360 - 400 4 springs. Use 18 springs, ma-...
  • Page 11 Square Barrel Engine Manual Service Manual www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 12 Square Barrel Engine Manual Service Manual :LUTCHES :LUTCHES & & 27a. 250 27a. 250 360 fiber clutch 360 fiber clutch 18 to 20 springs double 18 to 20 springs double 5 fiber plates 5 fiber plates ~ steel plates ~ steel plates &...
  • Page 13 Square Barrel Engine Manual Service Manual 27d. Second design bip, 27d. Second design bip, clutch used in all clutch used in all 1972 400 & SOlcc models. 1972 400 & SOlcc models. S steel splined plates S steel splined plates...
  • Page 14 14 bearing requires 14 Square Barrel Engine Manual Service Manual ball bearin~s on all ball bearin~s on all models. models. Note: The clutch nut must be Note: The clutch nut must be NOTES TYP!CAL TO ALL CLUTCP.ES NOTES TYP!CAL TO ALL CLUTCP.ES installed with "Loctite".
  • Page 15 Square Barrel Engine Manual Service Manual 28. Remove the lock tab from the clutch guide nut by lifting out. The lock tab is reuseable. Shown is a new lock tab and one properly bent to secure the nut. Not used in 501.
  • Page 16 Square Barrel Engine Manual Service Manual 30. Pull clutch center from clutch case, remove bronze bush. Remove clutch case an~ primary chain and clutch thrust washer. Note condition, if bent or grooved replace washer. www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 17 Square Barrel Engine Manual Service Manual www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 18 Square Barrel Engine Manual Service Manual )). Remove lock tab, shift linkage cover plate, and shift linkage pull rod. 10mm wrench, chisel and hammer. See Misc. section for proper indexing of shift mechanism when reassembling. 34. Remove kick starter shaft and...
  • Page 19 Square Barrel Engine Manual Service Manual 37. Remove spring from hook rachet - 37. Remove spring from hook rachet - needle nose pliers. needle nose pliers. Remove left hand case - by hand Remove left hand case - by hand and.
  • Page 20 Square Barrel Engine Manual Service Manual 41. The connecting rod side play shall be .019 - .020 inch when new. feeler gauge may replace the dial indicator. The thickness of the big end of the connecting rod when new is .665 to .670 inch.
  • Page 21 Square Barrel Engine Manual Service Manual 45. Remove main shaft and shifting fork from lower scroll - by hand. Grind here .030 inch Hax. 46. Remove lay shaft and shifting fork from upper scroll. CHECK to see if the shifting fork on the lay shaft is not touching second gear on the main shaft.
  • Page 22 Square Barrel Engine Manual Service Manual 47. Gear stack showing the positio- ning of the shifting forks. When fitting a new 1st gear to the lay shaft be sure it has the same amount of internal clearance (slop) as the 3rd gear on the lay shaft.
  • Page 23 Square Barrel Engine Manual Service Manual Replacing " cam spindle. Replacing "0" rings on shifting cam spindle. Remove engin Cases must b Remove engine seals and reinstall. Use an oven Cases must be heated approx. 250 a torch is n Use an oven or hot plate.
  • Page 24 Square Barrel Engine Manual Service Manual Removing the felt wick and re- taining spring. Removing the circlip from the shifting pawl. Removing the shifting pawl. 60. Removing the pawl spring. www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 25 Square Barrel Engine Manual Service Manual TECHNICAL TECHNICAL SECTION SECTION www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 26 Square Barrel Engine Manual Service Manual 61. Shift earn bush and shift pawl 61. Shift earn bush and shift pawl stud are not normally stud are not normally removed, removed, however, however, if worn, they are if worn, they are...
  • Page 27 Square Barrel Engine Manual Service Manual Carb adaptors, and air cleaner assy. Foot starter assembly 66. Ignition side assembly showing engine seal, roller bearing, and oil seal. 501 engine seals are external to the main bearings. www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 28 Square Barrel Engine Manual Service Manual .7, Drive side assembly showing seal and ball bearing, www.maicowerk.com Courtesy of vintagemaico@gmail.com...
  • Page 29 Square Barrel Engine Manual Service Manual www.maicowerk.com Courtesy of vintagemaico@gmail.com...