Malossi 3111473 Manual Download | Manualshive

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V4 HEAD

Capolavoro Malossi

05/2011 - 7313273

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Summary of Contents for 3111473

Page 1: ...V4 HEAD Capolavoro Malossi 05 2011 7313273...

Page 2: ...with a distribution system of 3500 sale points This fills us with pride and leads us to an increasingly greater commitment to offering innovative products Our company and our technicians are at your...

Page 3: ...re engine in particular ENGINE DISASSEMBLY Disconnect the battery Disconnect all cables making up the electrical system that goes to the engine and the starter Disassemble the complete exhaust unit Re...

Page 4: ...the coolant out of the circuit using the drain plugs After having completely drained the coolant out of the engine all of the coolant inlet and outlet couplings on the engine must be disconnected Remo...

Page 5: ...leaning detergents and carefully dry all parts Drain all of the oil out of the engine Remove the cover from the head Be careful not to damage the seals Remove the spark plug Loosen but do not remove t...

Page 6: ...ve the outside screws M6 chain side that connects the head to the crankcase Fig 1 part 12 Unscrew the four nuts M8 on the central stud bolts Remove the head and the original cylinder from the base of...

Page 7: ...k whether air bubbles appear inside the pipeline If so the valve must be disassembled and grinding performed even if this procedure has already been carried out It may also be necessary to repeat the...

Page 8: ...esent unevenness or a worn head Even if only one of these conditions is found to exist we advise you to replace both components as well as the valve return springs if the latter are not in perfect con...

Page 9: ...he valves as they were originally fitted Then proceed with the tightness test as described in the section entitled Valve tightness test ATTENTION The head lapping in must be done by an authorised work...

Page 10: ...econdaria raccordo scarico Secondary Air System SAS Exhaust Connection Conduit air secondaire raccord chappement A Raccordi acqua Coolant Connections Raccord eau B Sensore temperatura Temperature Sens...

Page 11: ...vorazioni necessarie per adattare la testa alle varie versioni di veicoli sono le seguenti A Condotto aria secondaria raccordo scarico stato previsto un foro non comunicante col condotto di scarico ch...

Page 12: ...icarli su quella Malossi utilizzando gli accessori forniti nel kit Non andr aggiunto nessun tubo al circuito originale ATTENZIONE i tubetti 1 e 2 Fig 8 non sono comunicanti se il motore necessita dell...

Page 13: ...delle versioni Euro 3 a due cavi Per poter applicare il sensore temperatura nelle versioni Euro 0 1 2 a un cavo previsto un adattatore fornito nel kit C Sonde temp rature La culasse es travaill e afi...

Page 14: ...9 ATTENZIONE dopo la modifica del pistone procedere ad un montaggio di prova Far ruotare l albero motore manualmente per verificare che le valvole non urtino il pistone NB consigliabile posizionare su...

Page 15: ...ONE PISTON AXIS AXE PISTON ASSE PISTONE PISTON AXIS AXE PISTON ASSE PISTONE PISTON AXIS AXE PISTON Fig 9 SCARICO EXHAUST ECHAPPEMENT ASPIRAZIONE INTAKE ADMISSION ASSE PISTONE PISTON AXIS AXE PISTON AS...

Page 16: ...kit 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 par...

Page 17: ...st holes in the slot found on the scraper ring segment Fit one of the two spin locks in the piston ensuring that it is perfectly inserted in its seat Insert the piston on the connecting rod and fasten...

Page 18: ...ng displaced compared to the second ring Place the rings as indicated in Fig 10 Using the special segment gripper pliers insert the new Malossi cylinder after it has been oiled A hook serving to lift...

Page 19: ...o true the head with the cylinder as it is shown in Fig 11 use the bushes supplied with the kit NB Pour les v hicules 125cc et 180cc pour le centrage de la culasse avec le cylindre comme en origine ut...

Page 20: ...he crankshaft to top dead centre by inserting a T wrench in the variator central nut To check the exact position of top dead centre you have to align the flywheel with the notch on the crankcase Fig 1...

Page 21: ...nd check to ensure that the gearing chain crown gear has remained aligned with the reference mark on the head If the crankshaft is blocked during the rotation do not attempt absolutely to force it und...

Page 22: ...er 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 Re mount the engine o...

Page 23: ...2 1 4 kgm Tightening torque for M6 screws crown gear and camshaft 12 14 Nm 1 2 1 4 kgm Total engine oil capacity see the original Use and maintenance handbook Recommended type Malossi F4 Full Synt Sp...

Page 24: ...Fig 14 and run the wires to the engine taking care that they will not be damaged Follow the wire that exits the injector and determine its connector disconnect this original connector and reconnect w...

Page 25: ...ot used Position it so it does not interfere with other wires or parts The ECU has three 3 different colored LEDs Fig 17 RED indicates a damaged ECU A damaged ECU is indicated if the red LED illuminat...

Page 26: ...ectly GREEN indicatestheECUisfunctioningcorrectly ifthegreenLEDdoesnotilluminatewhentheignitionisswitchedon thenthisindicates no power to the ECU Make sure that you have properly connected the wiring...

Page 27: ...rves correspond to varying levels of modifications 4 different maps curve 0 Malossi cylinder original cams original head and original exhaust system curve 1 Malossi cylinder Malossi cams original head...

Page 28: ...adjust the fuel curve from 20 to 20 in 3 different RPM ranges low 0 2 000 RPM mid 2 000 6 000 RPM high 6 000 max RPM To add fuel turn the potentiometers clockwise To subtrac fuel turn the potentiomete...

Page 29: ...justment Then select the base curve which corresponds to the vehicle level of modification This should make the vehicle run better at all RPMs In case the configuration setting of your vehicle does no...

Page 30: ...running so we suggest you to reset the parameters of auto adaptability after fitting Malossi Force Master 2 CDI You can proceed in two ways Electronically use the Piaggio palmtop connected to the diag...

Page 31: ...engine and reconnect the plug the parameters should be reset now In case these parameters have not been reset Malossi Force Master 2 CDI can work incorrectly Please note we suggest you to reset the p...

Page 32: ...s a line tending to narrow slightly from the carburetor valve on to the intake valve with a maximum cam angle of 2 At the same time it should not have any protuberances of any type edges expansions or...

Page 33: ...ower petrol or similar fuels LUBRICANT Recommended type Malossi F4 Full Synt Otherwise use the type of oil recommended by the manufacturer of the vehicle RUNNING IN and MAINTENANCE For breaking in and...

Page 34: ...perfect seal Never demand maximum performance from the engine until it has reached its optimum working temperature TECHNICAL FEATURES Piston Ultra compact with 3 rings Material special aluminium allo...

Page 35: ...ated steel alloy Cylinder 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 smoothi...

Page 36: ...si spessori 0 4 mm per testa Malossi 0 8 mm per testa originale 2 cylinder gaskets of different thickness are included in the kit 0 4 mm for Malossi cylinder head 0 8 mm for original cylinder head Dan...

Page 37: ...ments and suggestions you may wish to send us So goodbye from us all at Malossi and please accept our compliments Have Fun GOOD LUCK and see you next time The descriptions in this publication are not...

Page 38: ...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 declin...

Page 39: ...39 Fig 1 3 2 12 1 Fig 2 4...

Page 40: ...40 Fig 4 8 7 10 Fig 3 5 6...

Page 41: ...41 Fig 6 11 Fig 5 9...

Page 42: ...he c t chappement Posizione chiusura segmenti Position of piston ring closing Position fermeture segments Posizione delle linee di chiusura dei rispettivi segmenti Position of closing lines of each pi...

Page 43: ...43 Fig 12 Tacca sul carter Notch on the cranckcase Cran sur le carter Fig 13 14 13...

Page 44: ...44 Fig 14...

Page 45: ...45 Fig 15 B...

Page 46: ...46 Fig 16 D C...

Page 47: ...47 Fig 17 INIETTORE INJECTOR INJECTEUR LIBERO FREE LIBRE BOBINA DELL ACCENSIONE COIL BOBINE...

Page 48: ...YLINDRE CULASSE V4 ALLUMINIO ALUMINIUM ALUMINIUM H2 O 74 60 258 12 5 1 3113928 CILINDRO V4 CYLINDER V4 CYLINDRE V4 ALLUMINIO ALUMINIUM ALUMINIUM H2 O 74 60 258 12 5 1 3113958 CILINDRO V4 CYLINDER V4 C...

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