MALOSSI MULTIVAR: Generation 111 Variator - for 50cc + 70cc machines
TECHNICAL DATA
� Range of use from 28 mm to 88 mm of medium diameter (useful dimensions from 20 mm to 90/95 mm).
� Movable half pulley in a special alluminium-silicon alloy with treatment on surface.
� Sliding bushing in sintered self-lubricating bronze.
� Central hub in a special alloyed hardened and rectified steel.
� Roller guide cover in steel with head treatment and burnish (polish) on surface.
� Rollers in nylon with high resistance to wear and calibrated weight added with both glass ~fibe~ror special molybdenum sulphide.
� Driven pulley pressure spring in special hardened steel, stove-enamelled in yellow, white and red colour, depending on each calibration.
FITTING INSTRUCTIONS (Scooters)
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 not to lose or damage the tightening sockets and screws (Photo l a).
3) Unscrew the variator locking nut on the crankshaft (Photo l b).
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 3 a and 3 b).
6) In order to fit the driven pulley pressure spring, unscrew the locking nut of the bearer-block flange (Photos 4 a - 4 b), paying attention to the spring thrust.
7) Fit the new spring supplied in the kit.
Reassemble the clutch unit as shown in (Picture 6). Check the wear on your belt; if it isn't perfect, we suggest you replace it with one of our Malossi Belts or MHR in Kevlar. Reassemble the clutch unit with the belt fitted to the pulley, and tighten the lock nut (Picture 7).
9) Assemble the guides 5 into the cover 6 as shown in the variator assembly diagram, take care in fitting the assembly (Picture
.
10) Put the rollers 4 in the moving half-pulley 3 (Picture 9).
11) Insert the completed cover 6 in the moving half-pulley with rollers inside (Picture 10 - 11).
12) Insert the sleeve 7 (if any), on the crankshaft.
13) Insert the hub 2 into the moving half-pulley (Picture 12 - 13) and fit with caution the complete unit onto the crankshaft, making sure the rollers stay in place (Picture 14).
14) Fit the variator assembly, place the belt on the hub (Picture 15). Fit the fixed original half-pulley 1 or alternatively, the half-pulley supplied in the kit. Assemble the cooling fan and the fixing washer, if any.
15) Insert the clamping bolt and screw down with fingers (Picture 16).
16) 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 assembly the variator may be distorted (Picture 17).
17) The bolt on the crankshaft which fixes the variator must be tightened, as suggested in the assembly instructions.
ATTENTION
In the clutch kit of Yamaha 50 engine for the scooters models Aprilia: Amico, Sr; Malaguti: Centro, F10, F12 Phantom; Mbk: Booster, Fizz, Forte; Yamaha: Bws, Jog, Zest, Zuma; inside the antagonist spring set, there are two dust-covers in stamped plate.To fit in the new reinforced spring set, it is necessary to remove the external cover in order to avoid dangerous interference with the new spring.
WARNINGS
After a replacement of the belt or after a modification on the transmission gears, if you note a considerable lack of acceleration, we suggest you to remove again the crankcase, start the engine with the vehicle on its prop-stand, keeping the wheel lifted, accelerate at full throttle and check it the variator works properly If the variator remains locked, take it off and check if the rollers are wrongly fitted or if they have been damaged or if, for any reason, they cannot run (slip/move) in their tracks. If the rollers are worn or damaged, replace them with the MALOSSI original ones. Check that the movable pulley runs properly on its hub, remove any possible obstruction, DO NOT add oil, reassemble all parts correctly.
N.B: The quality of the transmission belt is very important in order to increase its life and the life of the variator. The belt has to be neither too rigid nor to soft.
The quality of the mix determines the right grip either in hot or cold conditions; a lack of power and performance can occur if the quality is poor.
MULTIVAR
In several cases it operates on the revolution gears between engine and wheels, as a gear which has two speeds more than the original gear. This is a great advantage in order to reach the best engine power distribution. MULTIVAR is sold already calibrated for engines provided with a high power couple, but you can set it as you like, simply replacing the rollers included in the kit with others having different weights (always insist on original MALOSSI parts).
DIRECTIONS HOW TO CALIBRATE THE VARIATOR:
Rollers: Increasing the roller weight, the engine is compelled to work with a lower number of revolutions, in this case it is necessary to have an engine with a strong power couple (power at low rate).
On the contrary, decreasing the roller weight, the engine works at a higher number of revolutions; in this case it is necessary to have an engine with less power couple and much more acceleration (power at high rate).
Spring: The pressure spring is vital to give the right amount of load to the transmission belt which must be balanced with the force developed by the centrifuge masses, in relation to the kind of engine coupling. If the belt slips, it will be necessary to fit a spring with more load. Then recalibrate the MULTIVAR. On the contrary if you fit a spring with too much load, a lot of engine power will be lost due to friction and the transmission belt, together with the pulleys, and these will be rapidly destroyed.
ATTENTION: Remarks
Multivar is supplied complete of all parts; it is not necessary to fit covers or other parts not provided in our kit. Only our Multivar Part Nos 51 3863, 51 7123, 51 7134,
51 7140, 51 7142, are supplied complete with this cover. As such the cover is just an aeshetic part which we supply for the variators having the exterior movable half-pulley.The covers fitted on the original variators have the function of retaining the grease. Multivar works without grease and the working parts are built with selflubricating materials; this is the reason why Multivar does not require the cover.
USEFUL SUGGESTIONS: Transmission Belt
Check the belt every 2000-3000 Km; be sure that it is of high quality and that there are no damages.It must not be worn 1,5 mm more than the A and B points of the original belt (see the drawing).If you have any doubt or problems, replace it with a reinforced belt made of Kevlar Malossi Racing Belt which you will find with its code number in the Malossi Catalogues.
MULTIVAR MAINTENANCE
In the case of racing use, check the wear of rollers and cursors every 1000-1500 Kms. If Multivar is used on the road, check these parts every 5000~-6000 Kms. Multivar has not to be lubricated and if it is used in very dusty places it must be washed frequently with oil and dried with compressed air.Use exclusively rollers and original Malossi spare parts; ask always for products packed and sealed up with Malossi mark. Order Malossi products specifying the part number mentioned on the instruction manual provided together with Multivar.
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