Following initial work

•   Further relieving and welding of front wheel inner arches to clear wider wheels and tyres
•   Rear window seal renewed
•   Rear side windows seals renewed
•   Spark plugs leads replaced with Taylor 8 mm HT wires
•   Petronix Flame-thrower high output coil installed
•   K&N air filter installed
 

Chassis Work Still To Do

•   Replace flexible brake hoses (old ones are getting soft), but need to be sourced.
•   Still not totally satisfied with suspension heights (back to front). Still some fine adjustments to be made.

My wife embracing 500 (note optional closed engine cover)



And optional open engine cover




Current Specifications

Specifications

Dimensions
Wheelbase               72.4 in
Length                   117 in
Width                  56 in       (Std. was 52 in)
Height                  50.0 in   (Std. was 52 in) 
Front Track               44 in
Rear Track               44.5 in
Coefficient of Drag            0.39

Corner Weights and Total Kerb Weight
Weighed  in June 2006 :
Front (Driver's Side)   = 248 lbs
Front (Pass. Side)     = 260 lbs
Front Total = 508 lbs (47%)
Rear  (Driver's)          = 295 lbs           
Rear  (Pass. Side)     = 294 lbs
Rear Total = 589 lbs (53%)
Total = 1,097 lbs

Vehicle Height
Each corner measured, from level ground, up to to bottom, outer, flat, edge of sill. Point of measurement, about 2” from where sill meets wheel arch, and forward or rearward towards vehicle centre.
Date: May 5, 2009
Notes: tyres properly inflated and with rear seats
Front LHS: 169 mm
Front RHS: 165 mm
Rear LHS: 166 mm
Rear RHS: 159 mm

Date: May 5, 2009
Notes: tyres properly inflated and minus rear seats
Front LHS: 169 mm
Front LHS: 167 mm
Rear LHS: 167 mm
Rear RHS: 169 mm

Performance
Max. Speed 65 mph   (105 mph)      (Std. was 61 mph (102 kph))
0 – 30 mph   4.2 sec
0 - 60 mph   35.9 sec            
30 - 60 mph   31.7 sec

Engine
Type                                       In-line 2 cylinder  652 cc  2 valves per cylinder  (Std. was 500 cc)
Bore x Stroke   77 mm x 70 mm       (Std. was 67.4 mm x 70 mm)
New 650 cc engine type                Type # : 126 A1 000             
New 650 cc engine number             Eng. # : 9649458
Crank/Oil Filter Pulley Rotation      Clockwise (when looking from rear)
Cylinder Head               Single-port 650
Inlet Valves               33 mm            (500 was 32 mm)
Exhaust Valves            28 mm            (500 was 28 mm)
Power                  25 bhp @  4,500 rpm
Torque                  31 lb/ft @  3,000 rpm
Maximum RPM               5,200 rpm
Compression Ratio            7.5 : 1
Carburettor               Weber 28 IMB 5/250
Air Filter Element            K&N clamp-on
Oil Filter                       Centrifugal
Oil (Summer Hot)            Mobil 1  15W50 Fully Synthetic  (2.6 litres)
Oil Pressure - Normal         36 - 43 psi
Oil Pressure - Warning Light Activates      8.5 - 14 psi
Spark Plugs (std.)            NGK BPR6HS         Denso W20FPR-U
Spark Plugs (optional)         NGK Iridium BPR6HIX      Denso Iridium 1WF20
                          E3 (not yet available in correct 1/2" reach)
Spark Plug Gap            0.024 to 0.028 in /  0.6 to 0.7 mm
Spark Plug (Thread Pitch x Dia.)   M14 x 1.25 (1/2" reach)
Spark Plug Tightening Torque      15 – 22 lb/ft (20 – 30 Nm)

Ignition Timing
Static Advance               10 degrees BTDC (equal to 13 mm round pulley)
Maximum Centrifugal Advance      18 degrees BTDC
Points Gap               0.018 to 0.021 in (0.47 to 0.53 mm)
Poly-V-Belts
Length  mm

Camshaft
Camshaft Label            26/57 (inlet dur. 263/exhaust duration 263/lift 0.367" or 9.325 mm )
Inlet Opens                26 degrees BTDC
Inlet Closes               57 degrees ABDC
Exhaust Opens            72 degrees BBDC
Exhaust Closes            17 degrees ATDC
Camshaft Lift               0.367 in (9.325 mm)
Replacement Sport Camshaft      Labelled : 40/85 (inlet dur. 305/exhaust dur. 310/lift 0.42" or 11.145 mm )

Cylinder Compressions
Fresh Engine               165 psi
Good Used Engine            145 psi
Getting Worn Engine         130 psi

Cooling System
Type                          Air Cooled by Engine Driven Fan

Transmission
Gearbox                      Fiat 126 4-speed manual (synchromesh)
Gear Ratios (1; 2; 3; 4)             3.25; 2.07; 1.30; 0.57
Final Drive Ratio                4.88:1
Gear Oil                      Mobil 1 10W40 Fully Synthetic (eng/gear oil for V-Twin
                         Bikes) 1.1 litres
                  

Clutch
Middle Barton have an off-the-shelf diaphragm clutch which has an up-rated diaphragm and centre plate. (This takes care of anything you're likely to throw at it, and it's easy to install)

Suspension
Front Spring               Stiffer, reverse eye single transverse leaf spring
Front Dampers               Telescopic Red Konis
Rear Springs               Stiffer coil springs (Green)
Rear Dampers               Telescopic Red Konis
Aforementioned Lowering Kit       (500Mania #AS001)   Lowers by 1.5” in
Front Wheel Bearing Kit
Rear Wheel Bearing Kit         Fiat 126P - QH # QWB241

Steering
Type                   Worm (screw) and sector  (This later "L" steering column has better switches for lights and wipers, a steering column lock with the ignition switch and a collapsible steering column for safety)
Front Tracking               Toe-in :   0 to 1/16 in   or :   0 to 2.0 mm   

Brakes
Front Type                (500Mania Kit # MV006) 1989-1997 MkIII Ford Fiesta
Front Disc Pads            Ford Fiesta Mk III (1989 to 1997) #FT1011E (90 R-00179/090)
Pad Adjustment            Automatic
Rear Type                       Hydraulic, Fiat 126P drum brakes
Brake Shoes               Fiat 126P - QH # BS544
Shoe Adjustment            Automatic
Rear Wheel Cylinders         Fiat 126P - QH # BWC3089
Parking Brake               Cable Operated
Master Cylinder            Larger tandem master cylinder from Fiat 126P
                                                        AKRON MALO # 89010
                                                        Other # on box - 791452
                                                        Hydraulic pipes from reservoir to master-cylinder are Jaguar parts.
Fluid                   Regular DOT 3 (not synthetic)

Wheel Bearings
Front                  Ford or Fiat 126P ?
Rear                          Fiat 126P - QH # QHB241

Wheels
Type                          Minilite Alloy
Size                          13 in x 7 in
Bolt Circle Diameter (PCD)      4 x 98 mm
Backspacing               4 in
Wheel Bolts                (Similar to used on VW, Audi, BMW, Mini, MB, etc. Tapered bolt - 12 mm
                                                        dia......,...... / 1.5 mm pitch / 24 mm thread length

Tyres
Make                   Sumitomo HTR200
Size                          175/50HR13
Pressures                       Recommended for Std. Wheels/Tyres : Front - 17 psi     Rear - 23 psi
                          My low profile radials : Front - 13 psi     Rear - 20 psi
Electrical
Alternator                Marelli or Polmot  33 Amp / 14.0 to 14.5 Volt
Starter Motor               12 V /  kW  Type B 76-05/12S pre-engaged
Battery                  12 V / 34 Ah (L235 mm;W133 mm;H198 mm)
Headlight Bulb               Wurth Firstec 12v 45/40 Watt (art.-Nr. 720 120 1)
Front Side/Signal Bulb         GE #7528     12v P21w/5W/BP2
Rear Signal Bulb            GE #7506     12v P21w/BP2
Tail/Stop Light Bulb            GE #7528     12v P21w/5w/BP2
Signal/Flasher Relay            Tridon Standard 12V (550) #20-1036-2 (3 terminal +/P/L)
                                                        + to battery
                                                        P to signal/indicator light
                                                        L to switch on steering column

Exterior
Paint Codes               Upper - Chrysler Flame Red (PPG # 4679)
                                                        Lower - 1994 GMC Medium Grey Metallic (WA 8798)
 
Alternative Paint 1            - Ferrari Rosso Corsa Glasurit FER 300/9
 
Alternative Paint 2             - Ecurie Ecosse Blue
                                                        - Scottish Flag Metallic Blue
                                                        - Lynx Flag Blue Metallic
                             Dupont (Lynx Flag Blue Metallic)
                                                                Code # B72
                                                                Ref. # F9915
                                                                Microfiche # M1657
                                                                Value Shade # 7
 
Ignition Key                Fiat #A3095
In-Line Fuel Filter