Malossi MULTIVAR Instructions Générales page 14

General assembly instructions
Scooters and motorcycles (Fig. 1 - 2)
1) Clean carefully the outside area of the
crankcase at the drive side, on which we will
work.
2) Remove the crankcase at the drive side, taking
care of no losing or damaging the tightening
sockets and screws (Photo 1a).
3) Unscrew the variator locking nut on the
crankshaft (Photo 1b).
4) Take off completely the original variator from
the crankshaft (Photo 2).
5) In case there is the calibrated spring
inside the kit, remove the clutch unit
(Photos 3a - 3b).
6) In order to fit the driven pulley pressure
spring, unscrew the locking nut of the bearer-
block flange (Photos 4a - 4b), paying attention
to the spring thrust.
7) Fit the new spring supplied in the kit
(Photo 5).
8) Reassemble the clutch unit as in origin
(Photo 6).
9) Check the wear on your belt; if it isn't perfect,
we suggest you replace it with one of our
Malossi Special or K Belts.
10) Reassemble the clutch unit with the belt
fitted to the pulley, and tighten the lock nut
(Photo 7).
11) Assemble the guides (3) into the cover
shown in the variator assembly diagram, take
care in fitting the assembly (Photo
12) Put the rollers (4) in the moving half pulley
(Photo 9).
(page 42)
13) Insert the completed cover
half pulley with rollers inside
14) Insert the sleeve (1), (if any), on the crankshaft
(Photos 13).
15) Insert the hub
(Photos 12)
unit onto the crankshaft, making sure the
rollers stay in place
16) Fit the variator assembly, insert the limiter
spacer (7)
hub (Photo
17) Fit the fixed original half pulley
alternatively, the half pulley supplied in the
kit. Assemble the cooling fan and the fixing
washer, if any.
18) Insert the clamping bolt and screw down with
(Photo
fingers
19) Slacken the belt pressing it in the middle, so
that it is not narrowed between the pulley
and the notched belt during locking of
the crankshaft bolt, or the assembly of the
variator may be distorted
20) The bolt on the crankshaft which fixes the
variator must be tightened, as suggested by
the manufacturer.
(2) as
8).
(5)
(2) in the moving
(Photos 10 - 11).
(6) into the moving half pulley
and fit with caution the complete
(Photo 14).
into the hub, place the belt on the
15).
(8) or
16).
(Photo 17).
14
Scooter
Fig. 1
8 7 6 5 4
Motorcycles
Fig. 2
1 8 7 6 5 4
3 2 1
3 2