Malossi MULTIVAR Instructions Générales page 17

5113790
Scooter Kymco - Sym (Fig. 5)
Fitting instructions
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-
(Photos 4a - 4b), paying attention
block flange
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).
13) The 2,5mm thick steel spacer, must be placed
between clutch and clutch bell - see
so as to allow the maximum opening of the
torque driver.
Fig. 5
CAUTION: for Euro 4 and Euro 5 vehicles
• Insert the 1 mm washer as shown in
• Remove the original upper spring guide
Fig. 6
(2) as
8).
(5)
Fig. 7
Fig. 5 -
Fig. 6
(Fig. 7)
17