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indiquée dans le tableau “

Données de montage”.

-  Pour rétablir le jeu des soupapes, utilisez une jauge d’épaisseur et les vis de réglage présentes sur les culbuteurs, portez le jeu des soupapes aux 

valeurs indiquées dans le tebleau “

Données de montage”.

-  Remontez le couvercle (

Fig. 1, point 6).

-  Remontez la pompe à eau (

Fig. 1, point 2) en contrôlant le joint d’étanchéité Oring et, s’il est endommagé, changez-le.

-  Versez dans le moteur la quantité d’huile Malossi 7.1 indiquée dans le tableau “

Données de montage”; utilisez l’huile du type conseillé par le 

constructeur du véhicule.

-  Contrôlez la bougie et, éventuellement rétablissez la distance entre électrodes ou remplacez-la avec une bougie du type indiqué dans le tableau 

“

Données de montage”.

-  Remontez le moteur sur le véhicule et reprenez tous les branchements comme ils étaient à l’origine.

-  To restore the valve clearance use “a tool to size the thickness” and control screws visible on the pivot, bring the valve clearance to the value 

indicated in the table entitled “

Assembly data”.

-  Re-assemble the cover (

Fig. 1, point 6). 

-  Re-assemble the water pump (

Fig. 1, point 2) checking the O-Ring and replacing it if it is damaged.

-  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”.

-  Re-mount the engine on the vehicle and reconnect all connections as they were originally.

nella tabella “

Dati montaggio”.

-  Rimontare il coperchio (

Fig. 1, part. 6).

-  Rimontare la pompa dell’acqua (

Fig. 1, part. 2) dopo aver controllato l’oring di tenuta ed eventualmente se risulta danneggiato sostituirlo.

-  Immettere nel motore la quantità di olio Malossi 7.1 indicata nella tabella “

Dati montaggio” del tipo raccomandato dalla casa costruttrice del veicolo.

-  Controllare la candela e ripristinare eventualmente la distanza degli elettrodi o sostituirla con una del tipo indicato nella tabella “

Dati montaggio”.

-  Rimontare il motore sul veicolo e ripristinare tutti i collegamenti come in origine.

Содержание 3114443

Страница 1: ...i tech Art 3114443 Art 3114349 Art 3114851 Art 3113792 Art 3116732 07 2013 7314349 Rev 08 2018 ...

Страница 2: ...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 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 o...

Страница 3: ...cylinder TECHNICAL FEATURES Cylinder Bore Ø 63 mm Stroke 58 6 mm Displacement 182 58 cc Compression ratio 10 6 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 ATTENTION dans le kit nous fournissons le boîtier éléct...

Страница 4: ... and upgraded heat exchange surfaces Piston Ultra compact with 3 rings Material special aluminium alloy with high silicon content low thermal expansion and a tin facing on the sliding surfaces Machining on machine tools with numerical control Lightened and reinforced Upgraded heat exchange surfaces Usinage par machines outils à C N à haute précision Accouplements cylindre piston avec tolérance d a...

Страница 5: ... 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 Segments Spéciaux à coulissement élevé et résistance mécanique très élevée I segment compression en acier nitruré e chromé II segment en fonte spéciale Segment racleur en troi...

Страница 6: ...4 different maps curve 0 fuel adjustment values zeroed out CDI excluded curve 1 Malossi cylinder and original exhaust system curve 2 Malossi cylinder and tuned exhaust system curve 3 Malossi cylinder Malossi cams and tuned exhaust system 3114443 Boîtier Électronique Réglage de la carburation 20 au min medium max Limiteur de tours 1000 RPM 4 programmes differents courbe 0 boîtier électronique exclu...

Страница 7: ... RPM 4 different maps curve 0 fuel adjustment values zeroed out CDI excluded curve 1 Malossi cylinder and original exhaust system curve 2 Malossi cylinder Malossi filter and tuned exhaust system curve 3 Malossi cylinder Malossi filter Malossi cams and tuned exhaust system 3114349 Boîtier Électronique Réglage de la carburation 20 au min medium max Limiteur de tours 1000 RPM 4 programmes differents ...

Страница 8: ...er 2 original exhaust system curve 1 Malossi Ø 63 cylinder Force Master 2 Power Cam Racing exhaust system curve 2 Malossi Ø 63 cylinder Force Master 2 Power Cam original exhaust system curve 3 Malossi Ø 63 cylinder Force Master 2 Racing exhaust system 3114851 Boîtier Électronique Réglage de la carburation 20 au min medium max Limiteur de tours 1000 RPM 4 programmes differents courbe 0 cylindre Mal...

Страница 9: ...rent maps curve 0 adjustment values zeroed out curve 1 Malossi cylinder original exhaust system curve 2 Malossi cylinder tuned exhaust system and Malossi filter curve 3 Malossi cylinder tuned exhaust system Malossi filter and Malossi camshaft 3116732 Boîtier Électronique Réglage de la carburation 20 au min medium max Limiteur de tours 1000 RPM 4 programmes differents courbe 0 valeur de réglage mis...

Страница 10: ... 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 INSTRUCTIONS DE MONTAGE Operations preliminaires...

Страница 11: ... and outlet couplings on the engine must be disconnected ONLY FOR SCOOTER 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 Videz le circuit de son liquide de refroidisseme...

Страница 12: ...ark found on the flywheel 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 Remove the rubber plug of the chain adjuster using a small 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 ta...

Страница 13: ... point 8 Remove the cylinder 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 Allentare i quattro dadi ciechi Fig 5 part 8 Sfilare la testa ed il cilindro dal basamento del motore Rimuovere il pistone dalla bie...

Страница 14: ... are not bent or present 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 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 wit...

Страница 15: ...st as described in the section entitled 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 Lavare e sgrassare scrupolosamente poi rimontare le valvole come in origine ...

Страница 16: ...ing to assemble the Malossi 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 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 ...

Страница 17: ...Insert the piston on the connecting rod and fasten it with the new spin lock 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 se...

Страница 18: ...tly 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 indicated in the table entit...

Страница 19: ...rom the gearing chain assembly opening and check to ensure 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 w...

Страница 20: ...ar has remained aligned with the reference mark on the head Fig 2 If the crankshaft is blocked during the rotation do not attempt absolutely to force it under 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 i...

Страница 21: ...dicated in the table entitled Assembly data Re assemble the cover Fig 1 point 6 Re assemble the water pump Fig 1 point 2 checking the O Ring and replacing it if it is damaged 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 o...

Страница 22: ...our vehicle in the front part of the scooter as indicated in the Vehicle use and maintenance ONLY FOR SCOOTER turn out the bolt Fig 6 point 9 and let go out all the air which is in the cooling circuit and close the bolt Restore the coolant level in the radiator and in the expansion tank to the mark Max Start the engine with the scooter on the stand and leave it to run revving it up slightly a few ...

Страница 23: ...hich comes from the CDI to the electrical tap connector Fig 15 part 14 WARNING once the wire is connected to the electrical tap connector we suggest to tape the wire bunch to avoid electrical tap vibrations damaging the wires Disconnect the injector and connect it to the two connectors on the Malossi CDI Fig 16 point 15 Connect the black wire which comes from the Malossi CDI to the negative pole o...

Страница 24: ...18 and run the wires to the engine taking care that they will not be damaged Apply the splice supplied in the Malossi kit to the yellow wire that exits the TPS connector on the butterfly housing Fig 13 part A Fig 11 part 10 Connect the yellow wire which comes from the CDI to the electrical tap connector Fig 12 part 11 WARNING once the faston is connected to the electrical tap connector we suggest ...

Страница 25: ...which comes from the Malossi CDI to the screw wich fixes the coil Fig 19 part C Locate the SMALL faston orange wire connected to the original 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 complete the circuit Fig 19 part D Fix the CDI The blue wire is not used Position it so it does not in...

Страница 26: ...art 16 Connect the yellow wire which comes from the CDI to the electrical tap connector Fig 20 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 21 Connect the female faston 1 supplied into ...

Страница 27: ...connect with the two connectors from the Malossi ECU Fig 25 part 17 Connect the black wire which comes from the Malossi CDI to the screw wich fixes the coil Fig 26 part 19 Locate the SMALL faston orange wire connected to the original 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 complete t...

Страница 28: ...28 WARNING If you want to bring the vehicle back to its original condition you must simply disconnect the cdi connectors and reconnect the Malossi connectors Fig 28 ATTENZIONE Qualora si voglia riportare il veicolo allo stato originale sarà sufficiente staccare i connettori della centralina e ricollegare i due connettori Malossi Fig 28 I T A L I A N O E N G L I S H F R A N Ç A I S ...

Страница 29: ... 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 Turn the throttle to the fully open 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 Taratura TPS throttle position sensor ...

Страница 30: ... 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 ATTENTION if one of the three trimmers is positioned on a red arrow then the vehicle will not start Ruotare il trimmer sullo zero Se nella procedura di taratura di MIN e MAX il led rosso lampeggia significa che la proce...

Страница 31: ...s 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 properly connected the w...

Страница 32: ...rves The curves are selected using the switch labeled MAPS These curves adjust fuel delivery based on throttle position and RPM providing the right amount of fuel under all conditions The 4 fuel curves correspond to varying levels of modifications Funzionamento La centralina Force Master 2 è mappata con 4 curve di base Le curve sono selezionate usando il commutatore contrassegnato con MAPS Queste ...

Страница 33: ...ust system curve 2 Malossi cylinder Malossi filter and tuned exhaust system curve 3 Malossi cylinder Malossi filter Malossi cams and tuned exhaust system 3114443 4 different maps curve 0 fuel adjustment values zeroed out CDI excluded curve 1 Malossi cylinder and original exhaust system curve 2 Malossi cylinder and tuned exhaust system curve 3 Malossi cylinder Malossi cams and tuned exhaust system ...

Страница 34: ...stem curve 3 Malossi Ø 63 cylinder Force Master 2 Racing exhaust system 3116732 4 different maps curve 0 adjustment values zeroed out curve 1 Malossi cylinder original exhaust system curve 2 Malossi cylinder tuned exhaust system and Malossi filter curve 3 Malossi cylinder tuned exhaust system Malossi filter and Malossi camshaft 3114851 4 programmes differents courbe 0 cylindre Malossi Ø 63 Force M...

Страница 35: ...tentiometer adjustment without having any other adjustments The Malossi CDI is supplied with curve 1 and zeroed potentiometers In addition to the 4 curves there are 3 potentiometers that allow you to fine tune the curve you select These potentiometers allow you to 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 La courbe dernière...

Страница 36: ...meter 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 result in adding or subtracting an amount of fuel proportional to how far the knob was moved from zero Calibration To select the right curve start by making sure that all 3 of the RPM pots are set to zero adjustment Then select the base curv...

Страница 37: ...t 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 manual meticulously Cette opération consentira au véhicule d obtenir prestations optimales dans tous les RPM Si la configuration préparation de votre véhicule ne corres...

Страница 38: ...nuts fastening the head 10 Nm 1 kgm Tightening torque for M8 screws crown gear and camshaft 24 Nm 2 4 kgm Total engine oil capacity 1 5 litres 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 kg...

Страница 39: ...rforming the test check to ensure that the oil seal on the guide is not leaking 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 engin...

Страница 40: ...ing angle of 2 No protuberances of any type are present Therefore it is perfectly jointed in all sections up to the exhaust silencer In this case as well there must not be any abrupt reductions in passage or increases in the passage sections GENERAL CARE Every time the cylinder kit is disassembled replace the head and cylinder bottom gaskets with a new series in order to guarantee a perfect seal N...

Страница 41: ...ns in this publication are not binding Malossi reserves the right to make modifications if it considers them necessary and does not accept any responsibility for any typographic or printing errors This publication replaces all previous publications referring to the updating matters contained therein WARRANTY Look up warranty terms in our website malossistore com These products are reserved solely ...

Страница 42: ... 42 Fig 2 4 3 Fig 1 2 1 6 ...

Страница 43: ... 43 Fig 3 Fig 4 5 ...

Страница 44: ... 44 Fig 6 9 Fig 5 7 8 ...

Страница 45: ...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 ...

Страница 46: ... 46 Fig 10 Fig 11 12 10 ...

Страница 47: ... 47 Fig 12 11 Fig 13 A ...

Страница 48: ... 48 Fig 14 A Fig 14 B ...

Страница 49: ... 49 Fig 16 15 Fig 15 14 ...

Страница 50: ... 50 INIETTORE INJECTOR INJECTEUR TPS LIBERO FREE LIBRE BOBINA COIL BOBINE Fig 17 ...

Страница 51: ... 51 C D Fig 19 Fig 18 ...

Страница 52: ... 52 Fig 20 16 ...

Страница 53: ... 53 Fig 21 ...

Страница 54: ... 54 Fig 22 1 3 2 Rosso Nero Red Black Rouge Noir Arancio Nero Orange Black Orange Noir Fig 23 ...

Страница 55: ... 55 Fig 24 4 ...

Страница 56: ... 56 Fig 25 17 ...

Страница 57: ... 57 Fig 26 19 ...

Страница 58: ... 58 Fig 27 18 ...

Страница 59: ... 59 Fig 28 ...

Страница 60: ... 60 ...

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