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Vittorazi Motors Moster 185 Plus Maintenance Manual Download Page 37

Moster 185 Plus  -  Maintenance manual  -  V1 

 

37 

 

3.7 Exhaust system 

 

 

 

 

Components to replace

 

 

 

 

Time limit 

Exhaust bushing (MY202a). 

50h 

Springs (M139, M139a, MP140, 
MP141) * 

150 

Gaskets (M137, MP155) * 

100h 

Self-locking nuts M8 (M019) * 

150h 

Exhaust manifold (MY200a). 

150h 

Silencer rubber (M141). 

150h or 1 year 

Silencer soundproofing material 

(MP159). 

150h 

Rivets (MP161). 

150h 

Silicone (LOCTITE 5900) 

150h 

Molykote grease.  

 

Loxeal 83-55/Loctite 270. 

 

 

 

 

 

 

Special tools 

Not required. 

 

Values 

Self-locking nuts M8: 32 Nm. 
Screw M8x25: 14 Nm. 

 

*Always replace it when disassembled. 
 
 

3.7.1 Manifold, exhaust bushing disassembly 

 
Remove the safety cables around the springs. 

Remove the 4 bushing springs and the 3 exhaust manifold springs. 
 

 

 

Summary of Contents for Moster 185 Plus

Page 1: ...MOSTER 185 Plus Maintenance manual release V1 2022 valid for MY20 MY22 versions ...

Page 2: ...Moster 185 Plus Maintenance manual V1 2 ...

Page 3: ...3 Airbox assembly 21 3 4 Carburettor 24 3 4 1 Carburettor disassembly 24 3 4 2 Carburettor maintenance 27 3 4 3 Carburettor assembly 28 3 5 Reed valve 31 3 5 1 Reed valve disassembly 31 3 5 2 Reed valve maintenance 33 3 5 3 Reed valve assembly 34 3 6 Gaskets 36 3 7 Exhaust system 37 3 7 1 Manifold exhaust bushing disassembly 37 3 7 2 Manifold exhaust bushing maintenance 39 3 7 3 Manifold exhaust b...

Page 4: ... 11 Flywheel coils 72 3 11 1 Flywheel coils disassembly Dual 72 3 11 2 Flywheel coils maintenance Dual 75 3 11 3 Flywheel coils assembly Dual 75 3 11 4 Flywheel coil disassembly Manual 81 3 11 5 Flywheel coil maintenance Manual 84 3 11 6 Flywheel coil assembly Manual 84 3 12 Transmission 86 3 12 1 Belt removal 87 2 12 2 Belt disassembly 88 3 12 3 Bell clutch disassembly 90 3 12 4 Transmission main...

Page 5: ... Plus Maintenance manual V1 5 3 13 3 Piston cylinder head assembly 113 3 14 Crankcase 118 3 14 1 Crankcase disassembly 118 3 14 2 Crankcase maintenance 123 3 14 3 Crankcase assembly 126 3 15 Tightening values 134 ...

Page 6: ...ling Then by sampling the complete motors are checked to assure the functionality of all the parts through a complete test of twenty minutes on the bench Note that the reliability performance and durability of the engine also strongly depend on the correct maintenance of which you are in charge In case you need further explanations you can contact directly the headquarters of Vittorazi Motors Plea...

Page 7: ...Moster 185 Plus Maintenance manual V1 7 Reading tips Attention danger risk Any situation or condition which may result in a serious danger Recommendation warning important advice ...

Page 8: ...e automatically determines the assumption of all risks and personal liability for personal injury or damage to third parties resulting from the activity Improper use of the products or improper technical service in relation to the specifications contained in the user installation and maintenance manual will held harmless the company from any liability for any damage due to the malfunctioning and i...

Page 9: ...t maintenance scheduling according to the Vittorazi program Do not keep the engine at full revs for more than 60 seconds Do not keep revs higher than 7 000 RPM during long cruising flights or long climbs The average power delivered by the engine during a flight should remain below the indicated threshold Contact the aircraft manufacturer for further clarification The temperature limit of CHT is 25...

Page 10: ...out exclusively with the original Vittorazi Motors parts and tools specified by Vittorazi in compliance with the specifications contained in the user installation and or maintenance manual of the products to ensure maximum safety and performance of the products the above mentioned procedures will be carried out by mechanics with proven experience in the ultralight aviation or general aviation or w...

Page 11: ...t by experienced mechanic and authorized dealers These are prescribed checks at certain interval times to avoid engine problems through preventative maintenance Note 1 or after a year 2 rope spring hooks or a new pull starter system 3 springs 4 each time the component is disassembled 5 head exhaust port decompressor hole 6 tensioning Caption Cleaning Check Measuring Replacement Lubricate with WD 4...

Page 12: ...ery 100 h Every 150 h Every 200 h Pre flight checklist Screws and nuts tightening Carburation from spark plug colour Spark plug Spark plug connector Carburettor Carburettor membranes 1 Airbox Snaplock Airbox Airbox sponge and sleeve 1 Reed valve petals Pull starter system 2 The table follows in the next page ...

Page 13: ...very 150 h Every 200 h Electric starter Kit exhaust bushing 1𝑠𝑡 joint Exhaust bushing 2𝑛𝑑 joint 3 Exhaust manifold with springs Soundproofing material silencer Silencer rubber 1 Gaskets cylinder carburettor reed valve exhaust silencer 4 Piston Piston roller bearing Head and cylinder 5 The table follows in the next page ...

Page 14: ...hours Before each flight Every 10 h Every 25 h Every 50 h Every 100 h Every 150 h Every 200 h O ring head 4 Rubber mountings engine exhaust 1 Oil seal carter case Crankshaft bearings Crankshaft Belt 6 Reduction bearings Centrifugal clutch Clutch bell ...

Page 15: ... plug 25 Nm 3 2 1 Spark plug disassembly Disconnect the connector and unscrew the spark plug 3 2 2 Spark plug maintenance Check the colour of the spark plug see user manual Use a feeler gauge to measure the distance between the spark plug electrodes Worn spark plug limit mm 0 9 If the distance between the electrodes is equal to or greater than the indicated limit or if scheduled maintenance is req...

Page 16: ... or the connection to the spark plug is not stable replace it Check the ignition cable there must be no cuts or cracks otherwise replace the ignition coil including ignition cable 3 2 3 Spark plug assembly The distance between the electrodes of the new spark plug must be 0 7 mm otherwise adjust Screw the spark plug into the head and tighten with the torque shown in the figure 25 Nm ...

Page 17: ...ce manual V1 17 3 3 Airbox Components to replace Time limit Sleeve with filter AT093a 100h or 1 year Snaplock MP093d 25 h Special tools Not required Values Clamp screw 2 5 Nm 3 3 1 Airbox disassembly Unhooking the safety strap ...

Page 18: ...ster 185 Plus Maintenance manual V1 18 Loosen the screw of the clamp securing the sleeve to the carburettor and remove the airbox Fold the sleeve inwards and remove it from the airbox Remove the Snaplock ...

Page 19: ...lean the airbox cavity with compressed air To obtain a good seal between the components degrease the connector of the airbox 1 and the internal part of the sleeve 2 with a product suitable for cleaning rubber the sleeve is made up of a mixture of NBR and PVC Check the integrity of the airbox Check the sleeve groove ...

Page 20: ...a comparison between a new component on the left and a worn one on the right Connect the Snaplock to the pin on the motor to check that the engagement is stable If the above components are damaged replace them immediately For routine maintenance follow the table Use extreme caution when checking as failure to replace damaged components can lead to detachment of the airbox and impact with the prope...

Page 21: ...eve of the airbox to the carburettor 1 after having inserted it rotate the airbox to fix the Snaplock 2 The airbox sleeve 1 must be completely inserted into the airbox connector 2 the fixing clamp 3 correctly inserted on the seat and aligned as in the figure Tighten the fixing clamp by applying the torque shown in the figure 2 5 Nm ...

Page 22: ...ttach the safety strap to the bracket between the vibration damper and the ignition coil ensuring that the strap is tightened firmly After installation check that there is no relative movement between the rubber sleeve and the Airbox connector ...

Page 23: ...Moster 185 Plus Maintenance manual V1 23 After installation check that there is no relative movement between the rubber sleeve and the airbox connector ...

Page 24: ...arburettor diaphragms and gaskets M097 100h or 1 year Loxeal 55 03 Loctite 243 50h or 1 year Special tools Walbro instrument for measuring metering lever Values Metering lever opening pressure 1 05 1 15 bar Screws M6x60 6 Nm Always replace it when disassembled 3 4 1 Carburettor disassembly Before disassembling the carburettor remove the airbox 3 3 Airbox ...

Page 25: ...emove the 2 Allen screws M6x60 1 from the airbox connector 2 Remove the connector of the Airbox 2 Remove the O ring 3 Remove the carburettor 4 Remove the following components from the carburettor flange 7 the gasket 5 the spacer 6 the gasket 5 ...

Page 26: ...1 26 Disassemble the carburettor by removing the components shown in the figure Remove the metering diaphragm 21 by sliding it sideways in the direction of the adjusting screws without lifting it up so as not to bend the metering lever 18 ...

Page 27: ...dition of the diaphragms they must be soft and free of cuts otherwise they must be replaced For routine maintenance follow the table Check the needle the tip must have a conical shape as shown in the figure otherwise replace it 8 Screws with captive washers fuel pump cover x4 16 Lunette screws x2 9 Fuel pump cover 17 Metering lever spring 10 Fuel pump gasket 18 Metering lever 11 Fuel pump diaphrag...

Page 28: ... spare parts kit the components identical to those to be replaced For example the photo shows two gaskets with a similar but not identical geometry therefore not interchangeable The incorrect choice of these components compromises the correct functioning of the carburettor Assemble the carburettor components without temporarily inserting components 20 21 22 23 Place the Walbro tool on the metering...

Page 29: ...e metering lever does not allow air to escape Carry out further tests by gradually increasing the pressure WB3A 1 05 1 15 bar Air must only escape from the metering lever needle within the pressure range indicated in the table In the event of a fault measure the height of the metering lever again and replace the spring 17 if necessary Once the above checks have been carried out fit components 20 2...

Page 30: ...asket 5 spacer 6 gasket 5 Position the carburettor 4 Insert the O ring 3 into the airbox connector 2 taking care not to pull it out of the housing Insert the 2 Allen screws M6x60 1 with threadlocker recommended Loxeal 55 03 Loctite 243 in the connector of the airbox 2 screw progressively then tighten with the torque shown in the figure 6 Nm ...

Page 31: ...imit Petals M082 50h Gaskets ME083 50h Loxeal 55 03 Loctite 243 50h Special tools Not required Values Screws M5x25 8 Nm Always replace it when disassembled 3 5 1 Reed valve disassembly Before disassembling the reed valve remove the airbox 3 3 Airbox and the carburettor 3 4 Carburettor ...

Page 32: ...ge 3 Remove the accelerator cable holder 2 Remove the following components from the crankcase 6 carburettor flange 3 gasket 4 reed valve 5 gasket 4 Remove the 2 screws 7 from one side of the reed valve Remove the stoppers 8 and petals 9 Carry out the same operations on the other side of the reed valve ...

Page 33: ...ght shows a typical break on worn petals Also check that the petals are not deformed looking at the inside of the reed valve the petals should close the opening perfectly photo on the left In the photo on the right you can see deformed petals that remain slightly raised If the previous checks are not passed or if routine maintenance is required replace the petals KO OK ...

Page 34: ...lace the petals 9 and position them against the bearing surface 10 Position the stoppers 8 and insert the 2 screws 7 Check that the petals rest perfectly on the surface of the reed valve see previous photos Carry out the same operations on the other side of the reed valve ...

Page 35: ... valve 5 with the gaskets 4 on the crankcase 6 Insert the carburettor flange 3 Position the accelerator cable holder 2 on the carburettor flange 3 Insert the 4 Allen screws M5x25 1 into the carburettor flange 3 tighten progressively then with the torque shown in the figure 8 Nm ...

Page 36: ... removing components in contact with them or in the event of leakage Also if the motor is not used for a long period of time check the condition of the gaskets For gasket replacement see the following chapters 3 4 Carburettor 3 5 Reed valve 3 7 Exhaust system 3 13 Piston cylinder head ...

Page 37: ...150h Silencer rubber M141 150h or 1 year Silencer soundproofing material MP159 150h Rivets MP161 150h Silicone LOCTITE 5900 150h Molykote grease Loxeal 83 55 Loctite 270 Special tools Not required Values Self locking nuts M8 32 Nm Screw M8x25 14 Nm Always replace it when disassembled 3 7 1 Manifold exhaust bushing disassembly Remove the safety cables around the springs Remove the 4 bushing springs...

Page 38: ...er 185 Plus Maintenance manual V1 38 Remove the exhaust manifold 1 the 2 self locking nuts M8 2 with washers 3 the exhaust flange with bushing 4 and the gasket 5 Remove the bronze ring 6 from the bushing 4 ...

Page 39: ... or silicone residue and check that it is flat Check the integrity of the exhaust manifold there must be no cracks or damaged areas otherwise it must be replaced For routine maintenance follow the table Check that the exhaust joints are regular Small defects on the surface sticking marks cracks steps must not prevent a regular motion of the joint ...

Page 40: ...hat the bronze ring 6 comes into contact with the seat of the bushing 4 to prevent leakage from the exhaust system Clean the bushing and cylinder from gasket residue Clean the end of the exhaust manifold 7 sand it with sandpaper and apply Molykote grease Clean the second joint 8 with an abrasive sponge e g Scotch Brite degrease it with solvent and apply Molykote grease ...

Page 41: ... the 2 self locking nuts M8 2 and the 2 washers 3 each time they are disassembled Insert the gasket 5 and the bushing 4 Add copper paste to the nuts Insert the 2 self locking nuts M8 2 with the washers 3 and tighten to 32 Nm Position the exhaust manifold 1 32 Nm ...

Page 42: ...nt Run 3 cables around the springs of the joint one cable for each spring insert a clamp on the ends and tighten with pliers Hook in the 4 springs of the bushing Run one cable around the 4 bush springs insert a clamp at each end and tighten with pliers Apply heat shrinkable hoses ...

Page 43: ...For MY20 Remove the Allen screw M8 1 the 2 washers 2 and the rubber 3 from the silencer support For MY22 Remove the Allen screw M8 1 the bushing 2 and the rubber 4 and the washer 5 from the silencer support Remove the 6 nuts from the upper end of the silencer MY20 MY22 ...

Page 44: ...nect the silencer 4 from the exhaust pipe and remove the gasket 5 Before disassembling de silencer mark the position of the end caps with an erasable marker Drill the 8 rivets centrally using a drill with a 5 mm diameter bit POSITION REFERENCE MARK ...

Page 45: ...enance manual V1 45 Use a heat gun to heat the end caps 6 9 in order to facilitate the release of the silicone Remove the following components from the silencer housing 8 the end caps 6 9 and the sound absorbing material 7 ...

Page 46: ...caps Thoroughly clean and degrease the ends and body of the silencer with a cloth Check the integrity of the silencer body both internally and externally there must be no cracks or damaged areas otherwise replace it For routine maintenance follow the table Check the integrity of the silencer band otherwise replace it ...

Page 47: ...ound absorbing material 7 around the inner tube 6 then position them in the silencer body 8 Fix the end caps on the body with 8 rivets respecting the references taken during disassembly Make sure that the end caps are fully inserted before fixing Wet the rivets with high temperature silicone Loctite 5900 before fastening and fix the end caps 6 9 on the body ...

Page 48: ... time it is disassembled Connect the silencer 4 to the exhaust pipe inserting the gasket 5 Insert the 3 nuts on the silencer then the 3 self locking nuts Tighten up to 10 Nm Tighten the first 3 nuts progressively to guarantee a correct alignment of the silencer 10 Nm ...

Page 49: ...nd the Allen screw M8x25 1 with threadlocker recommended Loxeal 83 55 Loctite 270 and tighten to 13 Nm MY22 version Insert the following components into the silencer support band 3 the spacer 2 the rubber spacer 4 the rubber spacer with washer 5 the Allen screw M8x25 1 with threadlocker recommended Loxeal 83 55 and tighten to 13 Nm 13 Nm 13 Nm ...

Page 50: ...21f 150h or 1 year Exhaust system rubber mountings M151a M151c 150h or 1 year Special tools Not required Values Self locking nuts M8 rubber mountings M021b M151c 18 Nm Self locking nuts M8 rubber mountings M151a 15 Nm 3 8 1 Rubber mountings disassembly When locking the rubber mountings during maintenance take care not to damage them ...

Page 51: ...Moster 185 Plus Maintenance manual V1 51 Remove the safety cable around the springs Remove the 4 bushing springs Remove the 3 self locking nuts M8 with washers ...

Page 52: ...Moster 185 Plus Maintenance manual V1 52 Remove the exhaust system Remove the 2 self locking nuts M8 with washers and the 2 rubber mountings from the motor mount ...

Page 53: ...Moster 185 Plus Maintenance manual V1 53 Remove the exhaust support Remove the 2 remaining engine rubber mountings ...

Page 54: ...Moster 185 Plus Maintenance manual V1 54 Remove 3 self locking nuts M8 and 3 rubber mountings of the exhaust system ...

Page 55: ... mountings there must be no cracks or detachment of material otherwise they must be replaced For routine maintenance follow the table 3 8 3 Rubber mountings assembly Replace the safety belts the 4 rubber mountings of the engine mount and the 3 rubber mountings of the exhaust system Position the exhaust support ...

Page 56: ...enance manual V1 56 Replace the 2 self locking nuts M8 Insert the 2 engine rubber mountings and the 2 self locking nuts M8 with washers and tighten to 18 Nm Insert the 2 remaining engine rubber mountings and tighten by hand ...

Page 57: ...8 Insert the 2 rubber mountings of the exhaust system shown in the figure the 2 self locking nuts M8 and tighten to 18 Nm Insert the exhaust system rubber mounting shown in the figure the self locking nut M8 and tighten to 15 Nm RUBBER 14 14 HARD M151c RUBBER 14 20 SOFT M151a ...

Page 58: ... 185 Plus Maintenance manual V1 58 Insert the exhaust system Replace the 3 self locking nuts M8 Insert the 2 self locking nuts M8 with washers on the rubber mountings shown in the figure and tighten to 18 Nm ...

Page 59: ...cking nut M8 with washer on the rubber mounting shown in the figure and tighten to 15 Nm Hook in the 4 bushing springs Run a cable around the 4 bushing springs insert a clamp on the ends and tighten with pliers Check chapter 3 7 for spring assembling operations ...

Page 60: ...00h Hooks spring MP057 100h Hooks MP055 100h Loxeal 24 18 Loctite 222 100h Loxeal 83 55 Loctite 270 100h HHS grease 100h Nanotech lubricant 100h Special tools Not required Values Screw M6x63 10 Nm Always replace it when disassembled 3 9 1 Pull starter system disassembly Remove the starter handle from the rope ...

Page 61: ...on given by the recovery spring is lost Gradually unscrew the 4 flange head screws M6x63 1 on the manual starter bracket 2 Follow the sequence highlighted by the blue arrows Maximum two complete turns per screw After removing the manual starter the cup 3 mounted on the flywheel will be visible ...

Page 62: ...move the columns and the M6x63 captive screws Remove the spring of the hooks 4 the 2 hooks 5 the washers 6 and the pulley 7 taking care to leave the recovery spring 8 in its place Remove the rope by untying the knot and pulling it off the pulley ...

Page 63: ...aintenance follow the table Check the hooks in particular the tips must not be damaged otherwise they must be replaced For routine maintenance follow the table Check the washers if they show signs of wear as in the picture replace them with new washers of the same thickness Check that the return spring is intact and not deformed otherwise replace it Insert the spring of the hooks on the central pi...

Page 64: ... area shown in the photo otherwise replace it Insert the spring of the hooks on the central pin and turn it if any blockage or jamming occurs the pin and structure must be replaced Failure to replace a worn pin can block the movement of the pulley and thus prevent the manual starter rope from being rewound correctly ...

Page 65: ... first and then the thicker ones Insert the washers 6 the 2 hooks 5 and the spring of the hooks 4 to assemble the pulley Position the pulley and the hooks according to the image below check that the gap between spring and washers are is between 0 35 and 0 45 mm if not remove the washers and use washers with different thickness ...

Page 66: ...Hold the pulley in place and wind 3 turns of rope counterclockwise Turn the pulley 3 turns anticlockwise to get the correct preload of the recovery spring Secure the rope with a cable tie and make a white mark on the rope When the engine will be installed on the paramotor check the position of the white mark remove the cable tie see the installation manual for more information ...

Page 67: ...185 Plus Maintenance manual V1 67 Screw the captive screw to the turrets Before final assembly of the manual starter on the engine check that the hooks are in the closed position otherwise they may be damaged ...

Page 68: ...hreadlocker Loxeal 24 18 Loctite 222 recommended into the manual starter bracket 2 Tighten the 4 screws progressively and tighten to 10 Nm according to the pattern identified by the blue arrows Maximum 2 turns per screw Check the installation manual for more installation operations 10 Nm ...

Page 69: ...Time limit Electric starter ME301 On condition Special tools Not required Values Screws M6x25 10 Nm 3 10 1 Electric starter disassembly Disconnect the battery Before disassembling the electric starter remove the pull starter system 3 9 Pull starter system and the belt 3 12 Transmission ...

Page 70: ...emove the 2 flange head screws M6x25 1 from the electric starter plate 2 Only for MY22 version Remove the o ring 2b from the starter plate Remove the 2 Allen screws M6x25 3 with washers 4 from the electric starter Remove the electric starter 5 ...

Page 71: ... starter assembly Insert the electric starter 5 into the crankcase housing Insert the 2 Allen screws M6x25 3 with washers 4 into the electric starter 5 and tighten with the torque shown in the figure Only for MY22 version Position the o ring 2b inside the reinforcement plate 2 Position the reinforcement plate 2 Insert the 2 flange head screws M6x25 1 in the plate 2 and tighten with the torque show...

Page 72: ... 243 200 h Special tools Piston lock ACC104 Flywheel puller ACC102 Values Nut M10x1 25 52 Nm Ignition coil to flywheel distance 0 3 mm Charging coil to flywheel distance 0 5 mm Always replace it when disassembled 3 11 1 Flywheel coils disassembly Dual Before dismantling the flywheel remove the spark plug 3 2 Spark plug and pull starter system 3 9 Pull starter system Screw the piston lock into the ...

Page 73: ...tenance manual V1 73 Unscrew the nut M10x1 25 Do not use a pneumatic impact screwdriver otherwise the piston may be damaged Remove the nut M10x1 25 with the washer 10 5x18 Screw the flywheel extractor into the starter cup ...

Page 74: ...ance manual V1 74 Turn the central pin of the extractor until the flywheel is removed from the crankshaft Remove the 4 Allen screws M5x20 1 with washers 2 from the coils 3 4 Remove the ignition coil 3 and the charging coil 4 ...

Page 75: ...ace it Check the ring gear 9 teeth if they show signs of wear replace the ring gear 9 Remove the 4 nuts M4 10 the 4 screws M4x16 8 the ring gear 9 from the toothed pulley 6 and replace it Measure the resistance of the coil if out of tolerance replace it COIL POSITION RESISTANCE IGNITION COIL HV CABLE EARTH 4 8 kOhm 10 25 C IGNITION COIL FASTON EARTH CONTNUITY OR CLOSE TO 1 OHM CHARGING COIL FASTON...

Page 76: ... piston block into the spark plug hole Insert the ring gear 9 on the toothed pulley 6 the 4 screws M4x16 8 and tighten with the torque shown in the figure Insert the 4 nuts M4 10 Replace the 4 screws M4x16 each time the ring gear is disassembled 4 1 Nm ...

Page 77: ...ft by aligning the key with the flywheel groove The position of the key and therefore of the flywheel determines the timing of the engine Replace nut M10x1 25 and washer 10 5x18 Insert the nut M10x1 25 with the washer 10 5x18 and tighten with the torque shown in the figure 52 Nm ...

Page 78: ...ce manual V1 78 Insert the ignition coil 3 and the 2 Allen screws M5x20 1 with washers 2 without tightening Place 0 3 mm shims between the ignition coil and the flywheel Tighten the ignition coil screws by hand Remove the shims ...

Page 79: ...rt the charging coil 4 and the 2 Allen screws M5x20 1 with washers 2 without tightening Place 0 5 mm shims between the charging coil and the flywheel in the areas highlighted in the figure Tighten the charging coil screws by hand Remove the shims ...

Page 80: ... Plus Maintenance manual V1 80 Insert the toothed pulley 6 on the flywheel 7 the 3 Allen screws M5x20 5 with threadlocker recommended Loxeal 55 03 Loctite 243 and tighten with the torque shown in the figure 8 Nm ...

Page 81: ...enance manual V1 81 3 11 4 Flywheel coil disassembly Manual Before dismantling the flywheel remove the spark plug 3 2 Spark plug and pull starter system 3 9 Pull starter system Screw the piston lock into the spark plug hole ...

Page 82: ...tenance manual V1 82 Unscrew the nut M10x1 25 Do not use a pneumatic impact screwdriver otherwise the piston may be damaged Remove the nut M10x1 25 with the washer 10 5x18 Screw the flywheel extractor into the starter cup ...

Page 83: ...r 185 Plus Maintenance manual V1 83 Turn the central pin of the extractor until the flywheel is removed from the crankshaft Remove the 2 Allen screws M5x20 1 with washers 2 from the coil 3 Remove the coil 3 ...

Page 84: ...if out of tolerance replace it COIL POSITION RESISTANCE IGNITION COIL HV CABLE EARTH 4 8 kOhm 10 25 C IGNITION COIL FASTON EARTH CONTNUITY OR CLOSE TO 1 OHM 3 11 6 Flywheel coil assembly Manual Screw the piston block into the spark plug hole Position the flywheel on the crankshaft by aligning the key with the flywheel groove The position of the key and therefore of the flywheel determines the timi...

Page 85: ...8 Insert the nut M10x1 25 with the washer 10 5x18 and tighten with the torque shown in the figure Insert the coil 3 and the 2 Allen screws M5x20 1 with washers 2 without tightening Place 0 3 mm shims between the coil and the flywheel Tighten the coil screws by hand Remove the shims 52 Nm ...

Page 86: ...114 150 h Centrifugal clutch MP102 150 h Belt MP117 100 h Clutch bell MP104 on condition Special tools Reduction key ACC181 Extractor Piston lock ACC104 Values Screw M8x16 25 Nm Screw M6x35 12 Nm Always replace it when disassembled Before proceeding with the next operations on the transmission remove the airbox 3 3 Airbox ...

Page 87: ...Moster 185 Plus Maintenance manual V1 87 3 12 1 Belt removal Remove the hexagonal screw M8x16 with washer from the pulley eccentric Remove the Allen screw M6x35 on the eccentric side ...

Page 88: ...Moster 185 Plus Maintenance manual V1 88 Turn the eccentric clockwise to release the belt tension Remove the belt from the pulley 2 12 2 Belt disassembly Remove the pulley and washer ...

Page 89: ...Moster 185 Plus Maintenance manual V1 89 Remove Seeger ring 1 from the seat on the pulley 2 Heat the central part of the pulley to 120 C Remove the eccentric 3 with the 2 bearings from the pulley 2 ...

Page 90: ...rings 1 4 the 2 bearings 5 with a bearing extractor and the spacer 6 from the eccentric 3 3 12 3 Bell clutch disassembly Remove the cover 7 from the clutch bell 9 for removal insert a self tapping screw M4x35 in the centre of the cover 7 Remove the Seeger ring 8 ...

Page 91: ...Moster 185 Plus Maintenance manual V1 91 Use an extractor with a maximum hook length of 4 mm Position the extractor 10 on the clutch bell 9 ...

Page 92: ...Moster 185 Plus Maintenance manual V1 92 Turn the central pin 11 until the clutch bell 9 is removed Screw the piston lock 12 into the spark plug hole ...

Page 93: ...with the piston lock Heat the clutch to facilitate disassembly Unscrew the clutch 13 until it is removed from the crankshaft 14 Do not use a pneumatic impact screwdriver otherwise the piston may be damaged Heat the clutch bell to 120 C Remove the Seeger ring 15 and the 2 bearings 16 17 from the clutch bell 9 ...

Page 94: ...residues from the grooves with solvent In the photo there are rubber residues on the clutch bell Check that the belt does not show signs of wear or damage otherwise as in photo it must be replaced If the belt has not been used for a long time check that it is soft otherwise it must be replaced For routine maintenance follow the table ...

Page 95: ...aced For routine maintenance follow the table Check the clutch the friction material on the pads must be intact and not show any scoring or burn marks otherwise it must be replaced For routine maintenance follow the table Check the axial play of the clutch pads it must not exceed 1 mm otherwise the clutch will damage the clutch bell The photo shows a damaged clutch bell due to excessive axial play...

Page 96: ... seats there must be no polished areas Also measure the diameter of the 3 seats and the internal diameter of the clutch bell the table shows the factory settings Dimension Factory settings at 20 C mm 1 41 970 41 980 2 34 980 34 990 3 34 980 34 990 4 89 45 89 55 ...

Page 97: ...Moster 185 Plus Maintenance manual V1 97 Measure the diameter of the bearing seat on the eccentric the table shows the factory settings Dimension Factory settings at 20 C mm 5 20 005 20 015 ...

Page 98: ... central part of the clutch bell to 120 C Insert bearing 6202 C 2HRS 16 into the clutch bell in the position shown in the figure Insert the Seeger ring 15 Insert bearing 6202 C 2Z 17 into the clutch bell in the positions shown in the figure Wait for the clutch bell to cool down ...

Page 99: ...Moster 185 Plus Maintenance manual V1 99 Screw the piston lock 12 into the spark plug hole Screw the clutch 13 onto the shaft 14 and tighten with the torque shown in the figure 20 Nm ...

Page 100: ...of the previous image simultaneously up to 80 C Pay the utmost attention when heating the rear bearing 16 because it has a rubber shield Place the clutch bell 9 and the Seeger ring 8 on the shaft Degrease the seat of the cover on the clutch bell Insert the cover 7 into the clutch bell 9 ...

Page 101: ...Moster 185 Plus Maintenance manual V1 101 Check that the cover 7 is positioned on the clutch bell 9 as shown in the figure the cover 7 must not be in contact with the shaft 14 ...

Page 102: ... both inner rings of the bearings 5 simultaneously up to 120 C Pay the utmost attention when heating the bearings 5 because they have a rubber shield Place the bearing 5 spacer 6 bearing 5 and Seeger ring 4 on the eccentric 3 Position the Seeger ring 1 on the eccentric 3 ...

Page 103: ...oster 185 Plus Maintenance manual V1 103 Heat the central part of the pulley to 120 C Insert the eccentric 3 with the 2 bearings in the pulley 2 Position the Seeger ring 1 in the seat inside the pulley 2 ...

Page 104: ...Moster 185 Plus Maintenance manual V1 104 Replace the washer 18 with the same thickness as the ones replaced Possible sizes range from 0 mm no washer to 0 6 mm Insert eccentric with pulley and washer 18 ...

Page 105: ...r 185 Plus Maintenance manual V1 105 3 12 7 Belt insertion Turn the eccentric to position it as in the figure This position facilitates the insertion of the belt Place the belt on the pulley and clutch bell ...

Page 106: ...Moster 185 Plus Maintenance manual V1 106 Insert the hexagonal screw M8x16 with washer into the eccentric of the pulley Insert the Allen screw M6x35 on the side of the eccentric ...

Page 107: ... frequencies indicated in the table are achieved use a frequency meter or mobile phone application Tighten the screw M8x16 to 25 Nm Replace the screw M6x35 every 3 belt retightenings Only replace with original Vittorazi components Tighten the screw M6x35 to 12 Nm Manually turn the pulley a few turns Check the belt tension again retighten if necessary Version First installation Retensioning Plus 13...

Page 108: ...in M011 circle clips M012 piston rings M013 150 h Roller bearing M009 150 h Cylinder M015 on condition Copper paste 100 h Special tools Not required Values Self locking nuts M8 16 Nm Always replace it when disassembled 3 13 1 Piston cylinder head disassembly Before disassembling the cylinder unit remove the spark plug 3 2 Spark plug the airbox 3 3 Airbox and the exhaust system 3 7 Exhaust system ...

Page 109: ...ove the 4 self locking nuts M8 1 with washers 2 from the engine head 3 Remove the head 3 the O ring 4 the cylinder 5 and the gasket 6 Close the inside of the crankcase with paper to prevent foreign bodies from accidentally falling into the engine ...

Page 110: ...Moster 185 Plus Maintenance manual V1 110 Remove the circle clip 7 the pin 8 the piston 9 and the roller bearing 10 Remove the 2 piston rings 11 and the circle clip 12 from the piston 9 ...

Page 111: ... the cylinder and internal surface of head Clean only the decompression hole on the cylinder with a 3 mm drill bit taking great care Immerse the piston cylinder and head in a in an ultrasonic bath containing cleaning liquid for aluminum The cylinder and piston belong to different selection classes according to tolerance Check the selection class engraved on the piston Measure the diameter of the p...

Page 112: ...clearance mm Maximum clearance mm A 65 990 66 000 65 945 65 955 0 035 0 055 0 15 B 66 000 66 010 65 955 65 965 C 66 010 66 020 65 965 65 975 D 66 020 66 030 65 975 65 985 E 66 030 66 040 65 985 65 995 at 20 C Determine the maximum clearance if equal to or greater than the indicated value replace the piston and or cylinder Check the piston and cylinder for signs of seizure otherwise replace them Fo...

Page 113: ... cylinder head assembly Replace the same thickness with one or more gaskets possible sizes 0 2 0 3 0 5 mm Insert the gasket 6 Oil the following components with the oil used for the mixture the roller bearing 10 the pin 8 the piston rings 11 and the piston 9 ...

Page 114: ...Moster 185 Plus Maintenance manual V1 114 Insert the 2 piston rings 11 into the piston grooves 9 paying attention to the position of the 2 piston ring retainers ...

Page 115: ...Moster 185 Plus Maintenance manual V1 115 Insert the circle clip 14 on the piston 10 respecting the position shown in the photo ...

Page 116: ...iangle on the top of the piston indicates the exhaust side Insert the roller bearing 10 the piston 9 the pin 8 and the circle clip 7 Replace the O ring 4 and the 4 self locking nuts M8 1 each time they are disassembled Fit the O ring 4 on the head 3 ...

Page 117: ...ing nuts M8 1 with washers 2 Tighten the nuts progressively then cross tighten with the torque shown in the figure Check the squish measurement on the pin axis acceptable values range from 1 35 mm to 1 55 mm If the squish is out of tolerance increase or decrease the thickness of the cylinder base gasket until the required result is obtained 16 Nm ...

Page 118: ...es Screws M6x35 40 10 Nm Screws M8x16 20 Nm Always replace it when disassembled 3 14 1 Crankcase disassembly Before disassembling the crankcase remove the airbox 3 3 Airbox the carburettor 3 4 Carburettor the reed valve 3 5 Reed valve the exhaust system 3 7 Exhaust system the rubber mountings 3 8 Rubber mountings the pull starter system 3 9 Pull starter system the electric starter 3 10 Electric st...

Page 119: ...Moster 185 Plus Maintenance manual V1 119 Remove the 4 countersunk head screws M8x16 1 and the crankcase support 2 Remove the 5 Allen screws M6x35 3 and 2 Allen screws M6x40 4 ...

Page 120: ...Moster 185 Plus Maintenance manual V1 120 Position the extractor 5 on the crankshaft 6 tighten the 4 screws M8 7 and turn the central pin 8 until the 2 case half are separated ...

Page 121: ...Moster 185 Plus Maintenance manual V1 121 Remove the oil seal 9 from the crankcase support 2 on the side shown in the figure Heat the manual starter side crankcase to 120 C Remove the bearing 10 ...

Page 122: ...oster 185 Plus Maintenance manual V1 122 Remove the crankshaft 6 using a press in the direction shown in the figure Heat the transmission side crankcase to 120 C Remove the bearing 11 and the oil seal 12 ...

Page 123: ... and the crankcase support with specific products for aluminium Check the case half check for integrity and abnormal marks Check the 2 bearing seats there must be no polished areas Also measure the diameter of the 2 seats the table shows the factory settings Dimension Factory settings at 20 C mm 1 46 960 46 980 2 46 960 46 980 ...

Page 124: ...ettings Dimension Factory settings at 20 C mm 3 15 000 15 005 4 20 001 20 007 5 20 001 20 007 Measure the clearance at the small end and big end of the connecting rod Factory nominal clearance mm Small end 0 008 0 017 Big end 0 022 0 031 at 20 C Check on the connecting rod that there are no areas of different color due to overheating ...

Page 125: ... Maintenance manual V1 125 Measure the eccentricity of the crankshaft the factory settings are shown in the figure Check that the seat of the key is undamaged If the above checks are not passed replace the crankshaft ...

Page 126: ... Maintenance manual V1 126 3 14 3 Crankcase assembly Heat the inner rings of the 2 bearings 10 11 and fit it on the crankshaft 6 Heat the transmission side crankcase to 120 C Insert the crankshaft 6 with the bearings ...

Page 127: ... crankcase to 120 C Carry out subsequent operations within a maximum of 5 minutes application of silicone and closing of the crankcase Carefully add silicone paste Three Bond 1215 to the crankcase profile as shown in the figure Height width silicone profile 2 mm x 2 5 mm ...

Page 128: ...t the 2 bushings are in their respective seats highlighted in the figure Close with the manual starter side crankcase still warm at 120 C Insert the 5 Allen screws M6x35 3 the 2 Allen screws M6x40 4 and tighten with the torque shown in the figure 10 Nm ...

Page 129: ... with a cloth except in the area shown in the figure between the plane of the reed valve and the cylinder base plane Wait for the crankcase to cool down Check the tightening of screws Insert oil into the 2 lubrication holes highlighted in the figure Check the sliding of crankshaft on the bearings ...

Page 130: ...5 Plus Maintenance manual V1 130 Replace the oil seal 9 each time it is disassembled Grease the oil seal 9 with FP Silicompound 225 and place it on the crankcase support 2 using the specific tool 13 to insert it ...

Page 131: ...Moster 185 Plus Maintenance manual V1 131 Carefully add silicone paste Three Bond 1215 to the crankcase profile as shown in the figure Height width silicone profile 2 mm x 2 5 mm ...

Page 132: ...ntenance manual V1 132 Insert the 4 countersunk screws M8x16 1 on the crankcase support 2 and then cross tighten with the torque shown in the figure Check that the hole shown in the figure is not blocked by silicone 20 Nm ...

Page 133: ...lace the oil seal 12 each time it is disassembled Insert the part A of the specific tool on the crankshaft Grease the oil seal 12 with FP Silicompound 225 and place it on the on the crankshaft using the part B to insert it Remove the part B and A ...

Page 134: ...83 55 Loctite 270 Loxeal 83 55 Loctite 270 Exhaust nuts 32 Nm M8 Copper paste Copper paste Exhaust support plate s nuts 18 Nm M8 Rubber mounting nuts M021b M151c 18 Nm M8 Rubber mounting nuts M151a 15 Nm M8 Carburettor flange screws 8 Nm M5x25 Paste Wurth 0893 921 501 Carburettor screws 6 Nm M6x60 Loxeal 55 03 Loctite 243 Loxeal 55 03 Loctite 243 Pulse line inlet brass hand tightening M6 Loxeal 53...

Page 135: ...er screw 10 Nm M6x63 Loxeal 24 18 Loctite 222 Loxeal 24 18 Loctite 222 Starter central pin screw 17 Nm M8x25 Loxeal 83 55 Loctite 270 Loxeal 83 55 Loctite 270 Eccentric rear screw 25 Nm M8x16 Eccentric side screw 12 Nm M6x35 Paste Wurth 0893 921 502 Electric starter screw 10 Nm M6x25 Electric starter fixing plate s screw 10 Nm M6x25 Wooden propeller screws 6 7 Nm M6 Carbon propeller screws 10 12 N...

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