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 performance.
Cylinder Specifications:
- Inner diameter of intake manifold: 15 mm
- Intake manifold connection diameter: 20 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: 45.0 mm
- Thread for decompressor: M10 x 1.5 mm
The intake manifold and exhaust flange are included in the scope of delivery.
Note:
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 5.
- The cylinder base must be turned down to readjust the compression ratio due to the shorter stroke. We recommend setting a squish gap of 0.8–1.0 mm.
- On models with an external clutch lever, the intake manifold must be extended; otherwise, the carburetor may come into contact with the clutch lever.
- The Athena adapters included in the kit do not fit these cylinders, as they only have an M6 hole. We therefore recommend ordering a compatible swiing® adapter.
It is well known that the Athena exhaust flange included in the cylinder kit can only be installed with laborious adjustments due to incorrect bores 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.
| Nominal diameter | 45 mm |
| Manufacturer | Athena |
| Material | Aluminum |
| Area of application | Tuning |
| Surface | sandblasted |
| Crankshaft stroke | 44 mm |
| Ø cylinder neck | 51.7 mm |
| Ø Outlet outside | 25.9 mm |
| Ø outlet inside | 19.5 mm |
| Ø Inlet inside | 14.3 mm |
| Inlet window | 23.4 x 12.6 mm |
| Thread inlet | M6x1 (standard thread) |
| Hole spacing inlet | 31.5 mm |
| Ø piston pin (B) | 12 mm |
| Outlet type | straight, clamped |
| Number of fixing points | 4 pcs |
| Hole spacing outlet | 50 mm |
| Thread outlet | M8x1.25 (standard thread) |
| Hole pattern [mm] | 56 (61) x 56 |
| Decompressor | M10x1.5 |
| Camouflaged | No |
| Sachs | 505 (with pedal shaft) - 1A (AT) , 2A (HG) , 2B (HG) 508 - 1 A 535 |
| Hercules | Great - 2 , 3 , 4 , 5 , Optima |
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Athena piston 45 mm #A | Sachs 504, 505
Nominal diameter: 45 mm · Manufacturer: Athena · Ø outside piston (A): 44.92 mm · Compression height (C): 28.2 mm · Total piston height (E): 45.2 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 · Ø piston pin (B): 12 mm · Tolerance group: A · Weight piston kit: 98 g
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Manufacturer: swiing® ingenious parts · Hole spacing: 50 mm · Material: Steel · Surface: galvanized (blue) · Width: 43 mm · Height: 25.5 mm · Ø inside: 22 mm · Ø outside: 26 mm · Ø mounting hole: 8.3 mm · Total length: 67 mm
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