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REED ENGINE - TECHNICAL FEATURES - To be able to fit this cylinder kit, bore the cran-
kshaft housing in the case. It is necessary to change the original crankshaft with a new Polini one,
part no. 210.0034. By fitting these parts you achieve a 134,73cc of displacement according to
the sprint scooter races' rules.
HOW TO PREPARE the INTAKE CASE FOR the POLINI BALANCED CRANKSHAFT-210.0033
It is quite easy to assemble it, but it is necessary to be familiar with the mechanic workings and to
own a manual milling machine.
PHOTO 1 - it is necessary to remove the case that covers the ignition that comes out the cylinder
plane. Work it at the milling machine in order to restore the cylinder plane.
PHOTO 2 - place the base and intake gaskets and fillet it by using the milling machine
PHOTO 3 - lengthen the intake transfer on the case till 4/5mm. from the edge. Be careful not to
damage the valve seal area on the case. Remove the old bearings and oil seals and replace them
with the new ones. Test the fastener and check the bases. If they are not in line level them and fit
the stud bolts supplied.
HOW TO PREPARE the REED CASE FOR the POLINI FULL-CIRCLE CRANKSHAFT-210.0034
It is quite easy to assemble it, but it is necessary to be familiar with the mechanic workings and to
own a manual milling machine.
PHOTO 4 - Close the original intake hole using the polyepoxide filler. In order to house the
crankshaft properly bore and lower the case using the milling machine as shown in pict. A.
PHOTO 1 - it is necessary to remove the case that covers the ignition that comes out the cylinder
plane. Work it at the milling machine in order to restore the cylinder plane.
PHOTO 5 - place the base and intake gaskets and, by using the milling machine, fillet the
transfers driven.
PHOTO 6 - By using the polyepoxide filler fill in the holes on the transfer driven and then fillet
them as shown in the photo. House the crankshaft and replace the bearings and the original oil
seals with the Polini ones part no. 280.0031 and 285.0111 (see technical table). Test the fastener
and check the bases. If they are not in line level them and fit the stud bolts supplied.
REPLACE THE CRANKSHAFT
Warm the cases using an hairdryer or a furnace at maximum 100/120°, and fit the bearings
respecting their perpendicularity. If the case reaches the assembly temperature, fit it manually
without using hammers or punches. After having placed the bearings and the oil seals, fit the
crankshaft (it will be easier to make it if the case still has the right temperature). Lubricate all the
parts with oil and after having placed the gasket, close the screws on the case in anti-clock way.
Check there is no friction and that the mechanic parts turn without pressure.
CYLINDER KIT ASSEMBLY
WARRANTY: before assembling the new Polini cylinder kit, carefully read the warranty manual
provided with the product.
Attention: NOT GUARANTEED GOODS. By using high sophisticated instruments in thermo-
static chamber, qualified technicians check the appropriate dimensions to establish the right con-
nection between piston and cylinder. The steadfastness in doing this gauging allows us to exclude
whatever possibility of seizure caused by a wrong connection between piston and cylinder; for
this reason THE GUARANTEE DOES NOT COVER THE CYLINDER GROUP. The assembling
of this cylinder group highly improves the performance; for this reason a complete service of the
block, of the connecting rod, ignition, and carburetion is recommended. We suggest to check the
and clean the exhaust system. Furthermore, according to the variations and alterations that have
been made to the carburetors and to the exhaust systems by the different manufacturers during
the years, we suggest a specific set up of the carburetion for each model. (The set up could be
very different from the data we have suggested in the assembling instructions).
To combine further Polini Motori's products, check our catalogues or visit our web site at
www.polini.com.
PROCEDURE: it is quite easy to assemble this kit since you have already closed the cases accor-
ding to the instructions, but it is important to carefully follow some precautions. Before assembling
the engine, accurately wash the cylinder, the piston and the head with petrol and blow in a jet of
compressed air; then lubricate the cylinder liner and all the moving parts with mixture oil. Assemble
the piston keeping the arrow towards the exhaust; if there is no arrow fit the piston with the ring
pins towards the induction. Check that the piston pin rings perfectly enter their housing. Assemble
the cylinder without the piston rings then rotate the crankshaft, check that the piston slides freely.
If a problem occurs, detect the cause and eliminate it. To achieve the maximum from your Polini
power unit, it is necessary to measure the "squish". In order to measure it, insert the base gasket,
assemble the cylinder and the piston and insert a tin wire on it, in the direction of the piston pin
(thickness: 1,5 mm). Torque the power unit remembering to lock up the fixing screw nuts crosswise.
Delicately turn the flywheel by passing three times through the top dead centre. Then disassemble
the head and check the thickness of the tin wire with a calliper (see the table for references). Once
finished, reassemble the head with its piston pin rings and again torque the fixing screw nuts cros-
swise. Insert the flow-guide pins in the reed valve, fit it in the cylinder and close with the manifold.
Advance adjustment: see technical table.
Because of the large power increase, in order to avoid the risk of exceeding the maximum
number of revolutions and of racing the engine, we suggest you using longer transmission gears
by substituting the gear set and/or the sprocket - gear set.
Attention! Silencers and tuned-up exhaust systems which replace the original ones need a
specific carburator's set up for the correct functioning of the whole group. Different calibrations
can be pointedly different from our data or from the recommended jets.
RUNNING-IN: in order to obtain the best performance from the cylinder group and to avoid
possible damages to the engine, during the first 30/40 minutes it is good to: increase the main
jet and warm the engine on the stand before using the bike. During the use check the cylinder
temperature (if during the run the temperature drops under 50° choke the radiator by using
some tape). Do not make long accelerations, do not drive for a lot of time with middle- range
open throttle (or open, it is very dangerous to run with the engine at medium-high rpm and the
middle-range open throttle). After 30/40 minutes, and before asking the engine the maximum
power, check the combustion (check the spark plug colour).
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