Pabatco · Fuji Heavy Industries · Engine Archive

F480 · F500K

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Firing up the two-stroke...

Pabatco · Fuji Heavy Industries · Engine Archive

F480
& F500K

Before Subaru defined the all-wheel-drive family car, Fuji Heavy Industries built small-displacement engines that powered a generation of American mini-bikes and trail machines. The F480 — a 79.6cc, 6.6 hp two-stroke running a Mikuni VM18 carburetor and 4-speed gearbox — and its 97cc sibling the F500K. The machines that started it all.

2
Stroke
80cc
F480 Displacement
100cc
F500K Displacement
F500K Engine Illustration

F500K · Technical illustration · Fuji Heavy Industries

What Made It
Different

The F480 was the first engine/gearbox assembly designed specifically for "midi" sized cycles — not a scaled-down motorcycle engine, not an adapted industrial unit, but purpose-built for the compact enduro and trail machines of the early 1970s. Pacific Basin Trading Company (Pabatco) brought it to the American market, and it showed up under five different brand names as a result.

At its core: a 79.6cc (4.86 C.I.) single-cylinder two-stroke inclined 25° forward, running loop scavenge with piston-port induction. The cylinder is cast Mechanite — a high-density grey iron chosen for its wear resistance — topped with an alloy head using a hemispherical combustion chamber. Ports are cast-in, not machined, with exhaust opening at 162° duration, transfer at 126°, and inlet at 131°.

The crankcase is split die-cast aluminum along the vertical centerline. Inside sits a balanced, single-throw forged steel crankshaft of "built-up" design — halves pressed onto a crankpin, with caged needle bearings at both ends of the connecting rod. The four-speed constant-mesh gearbox shares oil with the clutch, selected by a patented spring-loaded control shaft. Fuji called it simplicity personified, and they weren't wrong: normal service requires no special tools.

The F500K followed the same architecture, boring out to 53mm for 97cc and 8.5 hp at 7,500 rpm. The 100cc variant used a Mikuni VM20 carburetor and was offered with oil injection as a factory option on some models.

79.6cc

F480 Displacement

48mm bore × 44mm stroke. 7:1 compression. Loop-scavenged piston-port induction. 6.6 hp at 7,000 rpm.

97cc

F500K Displacement

53mm bore, same 44mm stroke. Mikuni VM20 carburetor. 8.5 hp at 7,500 rpm. Oil injection optional.

4-spd

Integrated Gearbox

Constant-mesh, foot-operated. Gear ratios: 12.32 / 7.16 / 4.99 / 3.84. Helical primary drive at 3.16:1.

Mikuni

VM18 Carburetor (F480)

18mm Venturi, diecast alloy body. Main jet #80, pilot jet #30, needle clip 4th notch. Integral float starter — no choke.

Kokusan

FP4107 Magneto

Flywheel type, 21.8W rated. Dual-coil system: ignition and lighting on the same flywheel. Timing: 25° BTDC. NGK B-8S plug.


Technical Data

Engine
Specifications

F480 engine

F480

Configuration25° inclined single-cylinder, 2-stroke, air-cooled, loop scavenged, piston port induction
Displacement79.6 cc (4.86 C.I.)
Bore × Stroke48 mm × 44 mm (1.89" × 1.73")
Compression Ratio7 : 1
Power Output6.6 hp @ 7,000 rpm
Max Torque5.06 ft·lbs @ 6,000 rpm
CarburetorMikuni VM18, 18mm Venturi — Main jet #80, Pilot jet #30, Needle clip 4th notch
Fuel Mix16:1 (first 10 hrs) · 20:1 (thereafter) — SAE 30W 2-cycle oil
IgnitionFlywheel magneto — Kokusan Electric FP4107 · Timing: 25° BTDC (0.102" / 2.6mm) · Breaker gap: 0.012"–0.015"
Spark PlugNGK B-8S · Gap: 0.024"–0.027" (0.6–0.7mm) · Reach: 3/8"
Transmission4-speed constant mesh, foot-operated — Ratios: 1st 12.32 · 2nd 7.16 · 3rd 4.99 · 4th 3.84
Primary DriveHelical cut gears · Pinion 19T · Primary 60T · Ratio 3.16:1
Clutch2-plate wet type, crankshaft-mounted, spring-tensioned · Spring free length: 0.79" (20mm)
CrankcaseDie-cast aluminum alloy, split vertical centerline · Forged steel crankshaft, built-up design
Cylinder / PistonCast Mechanite cylinder · Alloy head, hemispherical combustion chamber · High-temp alloy piston, 2-ring, chrome top ring
Port TimingExhaust 162° · Transfer 126° · Inlet 131°
Compression Pressure80–150 psi (normal operating range)
Transmission OilSAE 30W non-detergent (above 32°F) · SAE 20W (below 32°F) · Capacity: 1¼ pts (590cc)
StartingKick starter with roller clutch
Alternator Output21.8W rated · Green lead: 2.4V @ 2,500 rpm / 6.1V @ 8,000 rpm · Yellow lead: 4.5V @ 2,500 rpm / 8V @ 8,000 rpm
Cylinder Head Torque105 in·lbs (1.2 kg·m)
SourceF480 Workshop Manual — Pacific Basin Trading Co. (Pabatco), 1972 · Exclusively available on this site
F500K engine

F500K

ConfigurationSingle-cylinder, 2-stroke
True Displacement97 cc
Bore53.0 mm
Stroke44.0 mm
Compression Ratio7.0 : 1
Power Output~8 hp @ 7,500 rpm
CarburetorMikuni 20mm (22mm from 1974)
Transmission5-speed manual
CoolingAir-cooled
IgnitionMagneto
EraEarly 1970s

One Engine · Five Machines

Bikes That Ran the F-Series

The same Fuji engine — badged under five different names, sold through five different distribution chains. Each builder chose it for the same reason: nothing else in the class was built as well.

Indian ME100S Indian ME100S

Indian ME100S · c. 1972 · F500K engine

F500K · 100cc

Indian ME100S

The Indian ME100S was sold under the storied Indian brand name by Indian Sales Corporation from 1972 until operations ceased in 1977. "ME" stood for Mini Enduro, and the 100S indicated the 100cc displacement class. Powered by the Fuji F500K — a 97cc air-cooled two-stroke fed by a Mikuni 20mm carburetor, upgraded to a 22mm unit in 1974. Good for around 8 horsepower at 7,500 rpm and a top speed near 55 mph.

EngineFuji F500K, 97cc 2-stroke
Bore × Stroke53.0 mm × 44.0 mm
Compression7.0 : 1
Power~8 hp @ 7,500 rpm
CarburetorMikuni 20mm (22mm from '74)
Transmission5-speed manual
Top Speed~55 mph (88 km/h)
Weight175 lbs (79.4 kg)
Fuel Tank1.6 gal (6.05 L)
BrakesDrum front & rear
Sold ByIndian Sales Corporation
Production1972 – 1977
HPE Muskin El Gato HPE Muskin El Gato

HPE Muskin El Gato · 1970–1973 · F480 engine · Chrome Yellow

F480 · 80cc

HPE Muskin El Gato

HPE Muskin was a California-based company known for swimming pools — but in the late 1960s they turned to motorized vehicles. Their El Gato ("The Cat") refused to call itself a minibike. Muskin coined "Midi-Cycle" to set it apart: at 125 lbs, a 44-inch wheelbase, 16-inch wheels, and signature Chrome Yellow fiberglass bodywork — it was impossible to miss. Power came from Fuji's F480 80cc two-stroke mated to a four-speed constant-mesh transmission.

EngineFuji F480, 80cc 2-stroke single
Power6.6 hp (claimed)
Transmission4-speed constant-mesh
CoolingAir-cooled
Seat Height27 inches
Wheelbase44 inches
Weight125 lbs
ColorChrome Yellow (signature)
Production1970 – 1973
rupp
F480 / F500K

Rupp RMT80 & L100

Mickey Rupp founded his Mansfield, Ohio company in 1959, building snowmobiles, go-karts, and dune buggies before turning to motorcycles. The RMT80 used the Fuji F480 — a 79.6cc two-stroke making 6.6 hp at 7,000 rpm through a Mikuni VM18 carburetor and 4-speed gearbox — while the L100 stepped up to the F500K 97cc powerplant. Both machines reflected Rupp's practical, no-nonsense approach to off-road riding — functional, durable, and built for the American dirt trails of the early 1970s.

RMT80 EngineFuji F480, 80cc 2-stroke
L100 EngineFuji F500K, 97cc 2-stroke
RMT80 Transmission4-speed manual
L100 Transmission5-speed manual
RMT80 Wheels17-inch front / 16-inch rear
CoolingAir-cooled
Founded1959, Mansfield, Ohio
FounderMickey Rupp
Fuji Production Era1972 – 1975
Also MadeSnowmobiles, go-karts, dune buggies
eagle

Deckson Eagle 80 · c. early 1970s · F480 engine · newspaper advertisement

F480 · 80cc

Deckson Eagle 80

Advertised in the early 1970s as "The unbelievable adventure machine. Ready for the road, trail or track," the Deckson Eagle 80 was a dual-purpose mini-enduro sold at the eye-catching price of $299.75. Like several American importers of the era, Deckson sourced the proven Fuji F480 — a 79.6cc, 25°-inclined single-cylinder two-stroke producing 6.6 hp at 7,000 rpm through a Mikuni VM18 carburetor and 4-speed constant-mesh gearbox. The same air-cooled engine found in the HPE Muskin El Gato, paired with a lightweight trail-ready chassis and pitched as an all-arounder: street-legal enough for the road, tough enough for the dirt.

Documentation on the Deckson Eagle is scarce. The information here is sourced from a period newspaper advertisement. If you have additional records, photos, or a serial number, please get in touch.

EngineFuji F480, 80cc 2-stroke
CoolingAir-cooled
Intended UseRoad, trail & track
Original Price$299.75
EraEarly 1970s
SourcePeriod newspaper advertisement
chappy

Chaparral ST-T-80 & ST-T-100 · 1973 · Manufactured by Fuji Motors Corporation, Japan

F480 (80cc) · F500K (100cc)

Chaparral Sportcycles

The Chaparral is one of the most explicit examples of the F-series engine's reach. The cover of the Chaparral BE80F/BE100F Engine Owner's Manual states it plainly: "Manufactured by Fuji Motors Corporation, Made in Japan." Sold in three configurations — the ST-T-80 with the F480 and Mikuni VM18, the ST-T-100 with the F500K and Mikuni VM20, and the T-95 with a Comet TC-88N torque converter for automatic operation. The 80 and 100 models used a steel tube double-loop frame, telescopic forks, and adjustable 3-position rear shocks. A 6V/4Ah battery, 6V electrical system, and the same Kokusan magneto running the same NGK B-8S plug at 0.024"–0.027" gap.

80cc EngineFuji F480 · Mikuni VM18 (18mm)
100cc EngineFuji F500K · Mikuni VM20 (20mm)
Transmission4-speed constant-mesh (T-95: Comet torque converter)
FrameSteel tube, double loop
Front SuspensionTelescopic fork, 4-1/8" travel, coil spring oil dampened
Rear SuspensionSingle-action hydraulic, 3-position adjustable, 3" travel
Weight (ST-T-80)144 lbs (137 lbs off-road)
Weight (ST-T-100)146 lbs (139 lbs off-road)
Fuel Tank1.6 gal · 20:1 mix (16:1 break-in)
Battery6V · 4Ah
Chain420 roller preferred · 41 roller optional
Year1973

A Note on the Maker

The F480 and F500K were built by Fuji Heavy Industries — the company that began as Nakajima Aircraft in 1917, survived the war, and eventually became Subaru Corporation in 2017. These small two-stroke engines were among the earliest civilian products of that postwar rebirth. The engineering discipline built into every F480 is the same that later produced the Subaru Boxer.

Nakajima Aircraft 1917 Fuji Heavy Industries 1953 Subaru Corporation 2017

Documentation Archive

Engine Manuals

Service manuals, parts diagrams, and owner's documentation for the F480 and F500K engines. Scanned and digitized from original Fuji Heavy Industries and OEM sources. Downloads are free for personal and restoration use.

F480 Service Manual F480 Engine Service & Repair Manual

Fuji Heavy Industries · Original Issue

The complete 1972 Pabatco workshop manual for the F480 — covering two-stroke principles, clutch, magneto/alternator, cylinder & piston, engine case, fuel system (Mikuni VM18), spark plug diagnosis, and full supplementary specs. Published by Pacific Basin Trading Company, Athena, Oregon. This scan is exclusively available on this site.

Download PDF
Deckson Eagle 80 F480

Deckson Eagle 80 Parts & Service Manual

Deckson · OEM Issue

Deckson's factory service document for the Eagle 80, with exploded parts diagrams, torque specifications, and F480 engine wiring schematic.

Download PDF
F500K Service Manual F500K

F500K Engine Service Manual

Fuji Heavy Industries · Original Issue

Full factory service manual for the 100cc F500K engine. Covers the Kai-series updates versus the F480, piston ring specifications, and magneto service procedures.

Download PDF
Indian ME100S Service Manual F500K

Indian ME, MT, ML & MX Owner's Manual

Indian Sales Corp. · OEM Issue

The complete Indian-branded service document covering the ME100S, which used the F500K powerplant. Includes frame, suspension, and F500K engine chapters.

Download PDF
Rupp Owners Manual F500K

Rupp Owners Manual

Rupp Industries · OEM Issue · Printed in U.S.A.

Addition 1 of the Rupp RMT 80 Cycle Service Manual. Covers front fork disassembly and fork oil specs (right tube 105cc, left tube 125cc), steering bearings, full electrical system including battery, headlight, ignition switch/rectifier, brake switches, tail/stoplight and horn — plus complete wiring diagram and special Rupp tool kit (P/N 32756) for the F480 engine.

Download PDF Download PDF
Chaparral F480 & F500K

Chaparral 1973 Owner's Manual + BE80F/BE100F Engine Manual

Chaparral Sales Corp. · OEM Issue · Manufactured by Fuji Motors Corporation

Two documents in one: the 1973 Chaparral Sportcycles Owner's Manual covering all ST-T-80, T-95, and ST-T-100 models, plus the BE80F/BE100F Engine Owner's Manual published directly by Fuji Motors Corporation. Includes full chassis specs, wiring diagrams for both T-model and ST-model configurations, carburetor adjustment table, and troubleshooting guide.

Download PDF
Have a manual we're missing? If you own original Fuji, HPE Muskin, Deckson, Indian, Chaparral, or Rupp documentation not listed here, please get in touch — we'd love to scan and archive it for the community.

ME100 Parts

Parts for Sale

Parts from my personal collection for the Indian ME100S. All items are from acquired stock — condition noted on each listing. Purchase securely via PayPal.

Handlebars
Used
ME100S

Indian ME Handlebars — 11104001

ME series handlebars. Have scratches from being moved around over the years. Spots in the plating — peeling, rough areas and dimples. Far from perfect but good for a rider. They are straight.

$45
Skid Plate
Used
ME100

ME100 Skid Plate — 11104250

Part# 11104250. Has some scratches.

$30
Tail Light
Used
ME100

ME100 Tail Light Assembly & Bracket

Part# 11105062

$150
Chain Guard
Used
ME100

ME100 Chain Guard

Part# 11104145

$35
Horn
Used
ME100

ME100 Horn

Part# 1110511105009

$15
Brake Pedal
Used
ME100

ME100 Brake Pedal

Part# 11104190

$30
Brake Stay Rod
Used
ME100

ME100 Brake Stay Rod

Part# 13004147

$20