MAXI SCOOTER MULTIVAR VARIATOR - GENERAL ASSEMBLY INSTRUCTIONS
a) Thoroughly clean the external area of the drive side casing where you will be working.
b) Disassemble the drive side casing while carefully ensuring that the truing bushes and the screws for the latter
(Photo I a) are not damaged or lost.
c) Unscrew the variator lock nut on the crankshaft (Photo I b).
d) Completely remove the entire original ~variator unit by sliding it off of the crankshaft.
e) Disassemble the rear clutch unit in the kit when the spring has been provided to replace the original one (Photo 2).
f) To fit the spring, if present in the ~Malossi kit, the tightening nut on the clutch mass-
holder flange (Photos 3 a and 3 b) must be unscrewed and care must be taken with the thrust of the spring found under the clutch.
g) Fit the new spring supplied in the kit (Photo 4).
h) 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 Kevlar Drive Belts. Remount the clutch unit with the belt inserted in the pulley and tighten the lock nut according to the manufacturer's instructions (Photo 5).
i) Mount the sliders (5) on the cover (8) as shown in the Variator assembly diagram. Ensure that they are inserted flush.
1) Position the rollers (4) in the mobile split pulley (3) (Photo 6).
m) Insert the cover (6) complete with sliders over the mobile split pulley with the rollers inserted (Photo 7).
n) Insert the spacer (7), if present, on the crankshaft.
o) Insert the hub (2) in the mobile split pulley and carefully slide the complete unit on the crankshaft, ensuring that the rollers do not come out of their guides (Photo 8).
p) The Variator unit should be positioned flush and then position the belt on the hub. Mount the original stationary split pulley (1) or otherwise the one supplied with the kit. Mount the small fan and the fastening washer, if present (Photo 9).
q) Insert the tightening bolt and tighten it with your fingers (Photo 9).
r) 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 9 a, 9 b).
s) The bolt on the crankshaft fastening the variator should be tightened at the torque indicated by the manufacturer.
CAUTION: CAREFULLY READ ALSO THE PAGE ON DEFINED ASSEMBLY INSTRUCTIONS FOR SPECIFIC VEHICLES.
APRILIA Leonardo 250cc - MALAGUTI Madison 250cc - YAMAHA Majesty 250cc -
Part No 51 11225
Use the original roller guide cover (6) and the original sliders (5) after checking to ensure that they are in good condition. Should they prove to be excessively worn or damaged, replace them with original ~sliders.Use the original lubricating grease cover and the lubricant indicated by the manufacturer. For all vehicles outfitted with this variator, it is absolutely necessary that the contrast spring supplied in the kit be used.
Caution: Yamaha Majesty 250 - rear drum brake version. For this vehicle, the fastening holes on the grease container cover must be slightly enlarged in order for it to be fitted correctly (Photos I O a and 1 O b).
HONDA Foresight 250cc - Part No 51 11226
Use the original roller guide cover (6) after having checked it first. Should it prove to be excessively worn or damaged,
it must be replaced. Do not use lubricating
must be fitted for all vehicles outfitted with this variator.
CAUTION: Honda changed the guides for the torque drivers during the production phase, creating two versions which can
be identified by the printing
Therefore, Malossi supplies two springs in the kit, for
it the yellow spring that is 180 mm long on the FG torque driver and the white spring
HONDA Pantheon 125-150cc - Part No 51 11261
Use the original roller guide cover (6) after having checked it first. Should it prove to be excessively worn or damaged,
it must be replaced. The spring supplied
The Malossi variator operates completely dry and therefore there is no need to insert
HONDA CN 250cc - PIAGGIO Hexagon 250cc - Part No 51 11262
Use the original roller guide cover (6) after having checked it first. Should it prove to be excessively worn or damaged, it must be replaced. The original roller guide cover normally has blanking flash at the end of the roller guides that can damage your new rollers. We highly recommend that the flash be eliminated using an air mill and an abrasive milling cutter and thoroughly polishing the end part of the roller guides on the cover (6). It is not necessary to disassemble the torque driver unit as the original spring is used for this variator. The Malossi variator operates completely dry and therefore there is no need to insert lubricating grease.
SUZUKI Burgman 250cc - Part No 51 11323
It is not necessary to disassemble the torque driver unit as the original spring is used for this variator. The Malossi variator operates completely dry and therefore there is no need to insert lubricating grease.