Athena racing cylinders for Sachs 504 (with modifications), 505, 508, and 535 engines, which were installed in Hercules Prima M, 2, 3, 4, 5, and Optima mopeds, among others.
Thanks to the large intake port, overflow ports, and exhaust port, this tuning cylinder delivers a significant increase in power.
Cylinder Specifications:
- Intake manifold connection diameter: 19 mm and 24 mm
- Inner diameter of exhaust flange: 20 mm
- Exhaust flange connection diameter: 25.7 mm
- Distance between stud bolts on exhaust flange: 50 mm
- Exhaust flange thread diameter: M8
- Cylinder neck diameter: 51.6 mm
- Stroke: 44 mm
- Bore: 48.0 mm
- Thread for decompressor: M10 x 1.5 mm
The intake manifold with diaphragm system for Dell'Orto SHA or PHBG carburetors and exhaust flange is included in the scope of delivery.
Notes:
Spark plugs with long threads must be used.
For Swiss 504 engines (42 mm stroke), the following modifications must be made to the cylinder:
- Adjust the cylinder base and gasket as shown in Figure 6.
- The cylinder base must be turned down so that the compression ratio is readjusted to account for the shorter stroke; we recommend setting a squish gap of 0.8–1.0 mm.
- On models with an external clutch lever, the intake must be extended; otherwise, the carburetor may come into contact with the clutch lever.
- The adapters supplied by Athena do not fit these cylinders, as they only have an M6 hole. We therefore recommend ordering a compatible swiing® adapter.
Since experience has shown that the included steel diaphragm plates can break, we recommend replacing them with Karbonit diaphragm plates.
It is well known that the Athena exhaust flange included in the cylinder set can only be installed with laborious adjustments due to incorrect drill holes and a missing gasket. The swiing® exhaust adapter comes with a gasket and the appropriate countersunk screws and solves this problem without the need for any modifications. Please pay attention to the installation direction during assembly. The piston is inserted with the arrow pointing toward the outlet on the exhaust side.
You can find the components mentioned above for smooth installation, along with other tools, in the accessories section.
A quality product from the Italian manufacturer Athena.
| Manufacturer | Athena |
| Material | Aluminum |
| Surface | sandblasted |
| Crankshaft stroke | 44 mm |
| Nominal diameter | 48 mm |
| Ø cylinder neck | 51.8 mm |
| Ø Outlet outside | 26 mm |
| Ø Inlet inside | 14.7 mm, 17.8 mm |
| Inlet window | 31.9 x 36.2 mm |
| Number of fixing points | 4 pcs |
| Ø outlet inside | 19.4 mm |
| Thread inlet | M5x0.8 (standard thread) |
| Area of application | Tuning |
| Ø piston pin (B) | 12 mm |
| Hole spacing outlet | 50 mm |
| Hole spacing inlet | 32.5 mm |
| Outlet type | straight, clamped |
| Thread outlet | M8x1.25 (standard thread) |
| Hole pattern [mm] | 56/60 x 56 |
| Decompressor | M10x1.5 |
| Camouflaged | No |
| Sachs | 505 (with pedal shaft) - 1A (AT) , 2A (HG) 508 - 1 A 535 |
| Hercules | Great - 2 , 3 , 4 , 5 , Optima |
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Athena piston 48 mm #A | Sachs 504 / 505
Manufacturer: Athena · Nominal diameter: 48 mm · Ø outside piston (A): 47.94 mm · Ø piston pin (B): 12 mm · Compression height (C): 30.2 mm · Curvature (D): 1.94 mm · Total piston height (E): 59.05 mm · Number of piston rings (F): 1 pcs · Piston ring mold: Rectangular ring · Piston ring impact: Internal fuse (IS) · Piston ring height: 1.5 mm · Tolerance group: A · Weight piston kit: 123 g
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