Malossi 3117559 Manual Download Page 1

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i-tech

Art. 3117559 - (5517563)

HONDA

PCX 125 ie 4T LC euro 3 2012-> (JF47)

SH i ABS 125 ie 4T LC euro 3 2013-> (JF41E)

SH mode 125 ie 4T LC euro 3 (JF51E)

Art. 3117560 - (5517563)

HONDA

PCX 150 ie 4T LC euro 3 2014-> (KF19E)

SH i ABS 150 ie 4T LC euro 3 2013-> (KF13E)

Art. 3117561 - (5517567)

HONDA

FORZA ABS 125 ie 4T LC (JF60E)

04/2017 - 7317559

Summary of Contents for 3117559

Page 1: ...ro 3 2012 JF47 SH iABS 125 ie 4T LC euro 3 2013 JF41E SH mode 125 ie 4T LC euro 3 JF51E Art 3117560 5517563 HONDA PCX 150 ie 4T LC euro 3 2014 KF19E SH iABS 150 ie 4T LC euro 3 2013 KF13E Art 3117561 5517567 HONDA FORZAABS 125 ie 4T LC JF60E 04 2017 7317559 ...

Page 2: ...an increasingly greater commitment to offering innovative products Our company and our technicians are at your complete disposal to offer you a modern and faultless service The scooter fitted out with this kit must only be used for competition on a closed track it is strictly forbidden to use it on the road Please take note that to obtain optimum performance all mechanical parts of the vehicle mus...

Page 3: ...169 2 cc Compression ratio 12 2 1 Material primary aluminium alloy with a high content of hardened and tempered silicon cylinder liner with silicon carbide coating in a galvanic nickel die and crossed smoothing with two diamond passages with very limited tolerances Machining on machine tools with high precision numerical control Cylinder piston connection with an allowance of 0 05 mm Recalculated ...

Page 4: ...n and a tin facing on the sliding surfaces Machining on machine tools with numerical control Lightened and reinforced Upgraded heat exchange surfaces Piston rings Special rings with high sliding ease and very high mechanical resistance I ring compression in nitrided and chromium steel II special cast iron ring Three piece scraper ring made of chromium plated special steel alloy Piston Extra compac...

Page 5: ...be 0 125cc avec kit Malossi ø61 Pot d échappement d origine courbe 1 125cc avec kit Malossi ø61 Pot d échappement Malossi avec DB killer courbe 2 125cc avec kit Malossi ø61 Pot d échappement d origine courbe 3 125cc avec kit Malossi ø61 Pot d échappement Malossi avec DB killer art 3117561 5517567 curva 0 125cc con kit Malossi ø61 scarico originale curva 1 125cc con kit Malossi ø61 scarico Malossi ...

Page 6: ...les making up the electrical system that goes to the engine and the starter Disassemble the complete exhaust unit Remove the air filter housing Disassemble the fuel system from the cylinder head leaving it connected to the frame Disconnect the rear braking system The complete brake caliper must be removed keeping it connected to the vehicle s hydraulic system Drain the coolant out of the circuit u...

Page 7: ...ouplings on the engine must be disconnected Remove the rear wheel and the screws or studs fastening the engine to the frame and rear shock absorber At this point you have released the engine from the vehicle and we advise you to position it on a very clean workbench ready for the next procedures or to clamp it in a vice Après avoir vidé le moteur de tout son liquide de refroidissement vous devez d...

Page 8: ...el Fig 3 line up the reference marks on the flywheel and on the crankcase as shown in Fig 3 In order to turn the engine use the close bolt of the crankshaft Unscrew the screw of the chain adjuster using a screwdriver Insert the screwdriver into the hole and turn clockwise the screw till complete locking Fig 4 point 5 Remove the chain adjuster and the crown gear taking care not to let the gearing c...

Page 9: ...head and the original cylinder from the crankcase of the engine Remove the piston from the connecting rod As an extra precaution to prevent foreign matter from entering the crankshaft block it is best to close the block with a clean cloth Dévissez les quattre écrous Fig 6 point 7 Démontez la culasse et le cylindre d origine de l embase du moteur Enlevez le piston de la bielle Pour plus de précauti...

Page 10: ...s well as the valve return springs if the latter are not in perfect condition If it is necessary consult the Useful suggestions In the event of valve guide replacement for both assembly and disassembly the head must be heated prior to the procedure with a hair dryer or electric hot plate After the replacement of the guides re condition the valve seats with a specific milling machine in order to re...

Page 11: ...itled Valve tightness test Attention The head lapping in must be done by an authorised workshop Otherwise clean the base of the cylinder head on a sheet of 1000 grade emery positionned on a perfectly flate surface plate until it is totally white then carefully wash the cylinder head Fig 7 comme indiqué dans le paragraphe Test d Etanchéité des Soupapes Attention Il est indispensable d effectuer l a...

Page 12: ...take the cylinder wash it and degrease it Drop the cylinder along the cylinder unit locking stud bolts and without forcing it fit it in the engine block Check to ensure that there are no rough parts inside the crankcase preventing the passage of the cylinder steering shaft or other minor problems preventing free entry of the cylinder flush with the crankcase In the event of significant blocked ent...

Page 13: ...k It must be oiled prior to this procedure Insert the second spin lock ensuring that it is perfectly inserted in its seat PISTON RINGS assembling Fig 8 Insert the small scraper ring segment spring 5 in the respective slot found on the piston Insert the lower reed 4 and then the upper reed 3 which make up the scraper ring segment Fig 9 Fit the second segment with the word N facing the upper part of...

Page 14: ...cylinder from resting perfectly on the base of the crankcase Fit the chain guide shoe checking to ensure that it is perfectly positioned in its seat Fit the new head gasket and the two truing bushes Insert the head on the stud bolts and use one hook to extract the gearing chain from the upper circular cover on the head Tighten the four stud bolt proceeding crosswise and with the tightening torque ...

Page 15: ...e that the crown gear is aligned with the reference on the head If necessary shift the gearing chain by one tooth more or one less on the crown gear Be careful to check often to ensure that the crankshaft is not moving during the timing of the camshaft from the position indicated by the two reference marks aligned as shown in Fig 3 Proceed with chain adjuster assembly tightening the 2 M6 screws on...

Page 16: ...der any circumstances Check the timing of the timing system which evidently was not performed properly Then repeat the timing process and follow meticulously the procedure indicated here above After having checked to ensure that the crankshaft is at the top dead centre Fig 3 and the camshaft is positioned as indicated in Fig 2 check and if necessary correct the exhaust and intake valve for the pro...

Page 17: ...ed Put in the engine the amount of Malossi 7 1 oil indicated in the table entitled Assembly data using the type of oil recommended by the manufacturer of the vehicle Check the spark plug and if necessary re adjust the distance of the electrodes or replace it with one of the types indicated in the table entitled Assembly data Remontez le couvercle Fig 5 point 6 Remontez la pompe à eau Fig 1 point 2...

Page 18: ... the radiator of your vehicle with coolant through the pressure cap Restore the coolant level in the expansion tank to the mark Max Re mount the engine on the vehicle and reconnect all connections as they were originally Start the engine with the scooter on the stand and leave it to run revving it up slightly a few times so that the coolant reaches the working temperature of 60 70 C Switch the eng...

Page 19: ... the CDI to the electrical tap connector Fig 11 part 9 WARNING once the faston is connected to the electrical tap connector we suggest to tape the wire bunch to avoid electrical tap vibrations damaging the wires Follow the wire coming out of the injector and cut it at about 3 cm from the connector as shown in Fig 12 Connect the female faston 1 supplied into the kit to the original connector 2 by u...

Page 20: ...ector and reconnect with the two connectors from the Malossi ECU Fig 10 part 10 Connect the black wire which comes from the Malossi CDI to the screw wich fixes the coil Fig 16 part 11 Locate the SMALL faston connected to the green pin on the coil and disconnect it Insert the faston which comes from the Malossi ECU orange wire to the original coil Connect the original wire to the ECU s bypass to co...

Page 21: ...ectors Fig 17 TPS Throttle Position Sensor Calibration Fig 18 Rotate the LOW trimmer to the red arrow position Turn the ignition key to the ON position Wait for all three 3 LEDs to illuminate and then turn off Turn the ignition key to the OFF position Rotate the LOW trimmer to the ZERO 0 position Rotate the HIGH trimmer to the red arrow position ATTENTION Dans le cas on veuille remettre le véhicul...

Page 22: ... to illuminate and then turn off Turn the ignition key to the OFF position Rotate the HIGH trimmer to the ZERO 0 position If the red LED starts blinking while calibrating the MIN and MAX this means that procedure has not been carried out correctly and that the throttle was not positioned correctly In this case re do the TPS calibration procedure from the start Ouvrez complètement la poignée GAZ To...

Page 23: ...rossa non è possibile avviare il veicolo ATTENTION Fig 19 if one of the three trimmers is positioned on a red arrow then the vehicle will not start ATTENTION Fig 19 si un des 3 trimmer est positionné sur la flèche rouge il ne sera pas possible d allumer le véhicule Fig 19 ...

Page 24: ...al causes for this problem are 1 Battery voltage too low or too high 2 Fuel injection cable is damaged due to interference with the frame 3 Damaged ECU AMBER indicates the trimmers have been adjusted correctly GREEN indicates the ECU is functioning correctly if the green LED does not illuminate when the ignition is switched on then this indicates no power to the ECU Make sure that you have properl...

Page 25: ...ginale curva 1 125cc con kit Malossi ø61 scarico Malossi con db killer curva 2 150cc con kit Malossi ø61 scarico originale curva 3 150cc con kit Malossi ø61 scarico Malossi con db killer 5517567 curva 0 125cc con kit Malossi ø61 scarico originale curva 1 125cc con kit Malossi ø61 scarico Malossi con db killer curva 2 valori di regolazione del carburante azzerati centralina esclusa curva 3 valori d...

Page 26: ... 6 000 max RPM To add fuel turn the potentiometers clockwise To subtrac fuel turn the potentiometer counterclockwise With the potentiometer pointed straight up at the zero mark towards the Malossi logo that is 0 adjustment With the potentiometer pointed straight up at the mark is 20 With the potentiometer pointed straight up at the mark is 20 Adjusting the potentiometer between these points will r...

Page 27: ...un better at all RPMs In case the configuration setting of your vehicle does not correspond to any of those indicated in the paragraph Working it is possible to get a new tuning adjusting the potentiometers as above explained WARNING do not attempt to adjust while riding RUNNING IN and MAINTENANCE For running in and maintenance follow the instructions found in the Vehicle use and maintenance manua...

Page 28: ...al nuts fastening the head 10 Nm 1 kgm Tightening torque for M5 screws crown gear and camshaft 9 Nm 0 9 kgm Total engine oil capacity 1 litre Type original the original Use and maintenance handbook Sparkplug type manufacturer NGKCPR 9EA 9 Electrode distance 0 6 0 7 mm Valve clearance exhaust 0 15 mm intake 0 10 mm DONNEES DE MONTAGE Couple de serrage des écrous borgnes des goujons M8 22 Nm 2 2 kgm...

Page 29: ...aking fuel If there is leakage replace it with a new one USEFUL SUGGESTIONS We advise you to grind in the exhaust and intake valves whenever the head is disassembled Grinding must be carried out using the specific tool and a satisfactory fine abrasive paste designed for grinding valves To improve the performance of the engine it is advisable to perform a perfect jointing and finishing of the intak...

Page 30: ...the cylinder kit is disassembled replace the head and cylinder bottom gaskets with a new series in order to guarantee a perfect seal Never demand maximum performance from the engine until it has reached its optimum working temperature Control often the oil circuit of the engine the oil level and the oil quality We hope you found the above instructions sufficiently clear However if any points are n...

Page 31: ...This publication replaces all previous publications referring to the updating matters contained therein WARRANTY Look up warranty terms in our website www malossi com These products are reserved solely for races in locations reserved for those purposes and in accordance with the regulations issued by the competent authorities for sports events We decline any and all responsibility for improper use...

Page 32: ... 32 Fig 2 3 4 Fig 1 2 1 ...

Page 33: ... 33 Fig 3 Fig 4 5 ...

Page 34: ... 34 Fig 5 6 Fig 6 7 ...

Page 35: ...i Position of closing lines of each piston rings Position des lignes de fermeture des respectifs segments 4 2 1 3 Fig 9 Fig 7 Piano di riscontro Perfectly flat surface plate Surface parfaitement plane Carta abrasiva n 1000 Sheet of 1000 grade emery Papier abrasif grain 1000 Fig 8 2 Segmento 2nd Piston ring 2nd Segment Spigolo Sharp edge Angle 1 Segmento 1st Piston ring 1er Segment Smusso Rounding ...

Page 36: ... 36 Fig 10 10 ...

Page 37: ... 37 Fig 11 8 9 ...

Page 38: ... 38 Fig 12 ...

Page 39: ... 39 Fig 13 1 3 2 ROSSO NERO RED BLACK ROUGE NOIR ROSA BLU PINK BLUE ROSE BLEU BIANCO NERO WHITE BLACK BLANC NOIR ARANCIONE NERO ORANGE BLACK ORANGE NOIR ...

Page 40: ... 40 Fig 14 ...

Page 41: ... 41 Fig 15 ...

Page 42: ... 42 Fig 16 11 12 ...

Page 43: ... 43 Fig 17 ...

Page 44: ... 44 INIETTORE INJECTOR INJECTEUR LIBERO FREE LIBRE CAVO ALIMENTAZIONE ALIMENTATION CABLE CÂBLE ÉLECTRIQUE TPS INIETTORE INJECTOR INJECTEUR Fig 18 ...

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