Technical Features - Malossi MULTIVAR 2000 Manual Del Usuario

MULTIVAR 2000 MAXI SCOOTER - GENERAL INSTRUCTIONS

Technical features

• HALF-PULLEY made of aluminium alloy with
silicon content, machined on very high-
precision CNC machines and diamond-
finished, with recalculated profiling of the roller
sliding guides.
• Sliding BUSHING made of self-lubricating
sintered steel.
• HUB made of alloyed steel with sliding surface
featuring a hard chromium facing that is ground
and lapped.
• CALIBRATED, HIGHLY RESISTANT HTROLL rollers
made of CPT with a specific formula.
ATTENTION:
Always verify that the correct components are
being used, during assembly, so that the variator
nut will seat fully and make sure the hub-spacer
assembly, wherever present, has the same total
dimension as the original. The ever-changing
engine designs may cause a compatibility issue
for Malossi products. In order to avoid damage to
the vehicle we ask you to make sure the assembly
is correct. We are not responsible for any
damages to the vehicle.
General assembly instructions
(page 127)
1) Thoroughly clean the external area of the
drive side casing where you will be working.
2) Disassemble the drive side casing while
carefully ensuring that the truing bushes and
the screws for the latter (Photo 1a)
damaged or lost.
3) Unscrew the variator lock nut on the
crankshaft (Photo
4) Completely remove the entire original variator
unit by sliding it off of the crankshaft.
5) Disassemble the rear clutch unit in the kit
when the spring has been provided to replace
the original one
6) To fit the spring, if present in the Malossi kit,
the tightening nut on the clutch mass-holder
flange (Photos 3a - 3b)
and care must be taken with the thrust of the
spring found under the clutch.
7) Fit the new spring supplied in the kit
(Photo 4).
8) Reassemble the clutch unit as it was
previously. Check the belt for wear and if it
is not in perfect condition, we suggest that
you replace it with one of our Malossi K Belts.
Remount the clutch unit with the belt inserted
in the movable half-pulley and tighten the
lock nut according to the manufacturer's
instructions (Photo
9) Mount the sliders
in the variator assembly diagram. Ensure that
they are inserted flush.
10) Put the rollers
(Photo 6).
11) Insert the cover
over the movable half-pulley with the rollers
inserted (Photo
12) Insert the spacer 7, if present, on
the crankshaft.
are not
13) Insert the hub
and carefully slide the complete unit on the
1b).
(Photo 2).
must be unscrewed
5).
5 on the cover 6 as shown
4 in the movable half-pulley 3
6 complete with sliders
7).
2 in the movable half-pulley
30
crankshaft, ensuring that the rollers do not
come out of their guides (Photo
14) The variator unit should be positioned flush
and then position the belt on the hub. Mount
the original fixed half-pulley 1
one supplied with the kit. Mount the small fan
and the fastening washer, if present
15) Insert the tightening bolt and tighten it with
your fingers (Photo 9).
16) Loosen the belt and tighten it in the middle
in such a manner that when the crankshaft
bolt is being closed, the timing belt is not
caught between the pulleys, thereby imitating
the packet closure of the entire variator unit
(Photos 9a - 9b).
17) The bolt on the crankshaft fastening the
variator should be tightened at the torque
indicated by the manufacturer.
CAUTION: CAREFULLY READ ALSO THE
SPECIFIC ASSEMBLY INSTRUCTIONS FOR EACH
VEHICLE, IF GIVEN.
8).
or otherwise the
(Photo 9).