Idiomas disponibles
Idiomas disponibles
OVER RANGE MHR
Warnings:
We advise you to check belt wear. When the time comes
to change the belt, use an original Malossi belt of the same
type, otherwise Over Range will not longer deliver its habitual
towering performance.
Fitting Instructions
• Clean the whole scooter, especially the outside of the
housing on the transmission side you're going to work on.
• Remove the casing on the drive side, taking care not to
damage or lose the truing bushes and screws
• Unscrew the securing nut of the speed variator on
the crankshaft, and remove the ventilated split pulley
(Photo
1b).
• Completely remove the entire original variator unit
(Photo
2), withdrawing it from the crankshaft.
Important:
To install the new wider range variator on Minarelli and
Yamaha engines, you have to remove the components of the
electrical starting system located inside the drive casing.
Procedure.
Unscrew the two socket head screws securing the restraint
flange of the starting pulley, remove the pulley itself, plus
the entire drive unit on the crankshaft, and remove the
starting motor.
• Dismantle the rear drive unit
• Remove the clutch from the original rear drive unit taking
care when unscrewing the nut from the spring pre-loading
device
(Photo
4a-4b).
• Carefully check the original clutch and, if the friction
material is excessively worn or if the springs yield, replace it
with a Malossi DELTA CLUTCH.
• For Piaggio engines (OVER RANGE art. 6114215 and
6114216). Dismantle the original spring-guide
without damaging it, using two screwdrivers for leverage
between the pulley and the spring-guide.
• Carefully clean all parts of the OVER RANGE unit plus any
original parts, using a suitable de-greasing product, and dry
them perfectly.
• Pick up the fixed split pulley and fit the guide-bush for
the seal rings on the threaded part of the hub, and apply
molybdenum grease on the hub.
• Take the mobile split pulley and apply a generous amount
of molybdenum grease inside the hub and along the cam
tracks.
• Fit the mobile split pulley on the fixed split pulley, taking
care over the seal rings.
• Fit the two O-rings in the cavities of the hub of the mobile
split pulley and fit the three guide-pins in the relevant
position holes on the hub of the fixed split pulley.
Important:
There are two sets of cam tracks in the hub of the Malossi
driven split pulleys. The only diff erence between the tracks is
their angle with respect to the pulley axis.
(Photo
1a).
(Photo
3a-3b).
(Photo
5),
To obtain the best acceleration, the engine must be
maintained as near as possible to its maximum power level.
You are recommended to use the tracks with a tighter angle
as shown with letter
(a)
in
If your scooter delivers a gear ratio curve with a fall off in
engine revs when accelerating, you can use the wider angle
tracks
(b)
to delay the gear change moment.
• Fill the 6 helical slots of the mobile split pulley hub with
grease and close the torque driver unit with spring-guide,
making sure that the external parts are fully de-greased.
• fit the spring on the spring-guide and re-install the clutch
as before, tightening the nut to the tightening torque
recommended by the hub manufacturer
• Before installing the torque driver unit on the main shaft of
the final reduction gear, fit the belt between the two driven
split pulleys. Then, while restraining the belt with your
hands, fit the unit on the small shaft shown above up to the
stop point
(Photo
7).
Important:
For MINARELLI AND YAMAHA engines, you have to lower
(using an air mill and a cutter) the ribbed section on the lower
and upper part of the drive casing, otherwise it would come
into contact with the new pulley and driving belt and damage
them totally
(see
Fig.2).
• Next, firmly join the remaining parts of the ribs to prevent
the belt being damaged in any way while the motor is
operating.
• At this point, carefully clean any machining chips off the
casing and begin re-installing.
• Check the original clutch bell, making sure it is already
reinforced, does not show any signs of wear or faults,
otherwise replace it with a Malossi SAFETY CLUTCH BELL or
WING CLUTCH BELL.
• Fit the clutch bell on the main shaft of the final reduction
gear and tighten the nut, according to the instructions
supplied by the vehicle manufacturer.
5
Fig.
1.
(Photo
6).
