MAXI SCOOTER MULTIVAR VARIATOR - GENERAL ASSEMBLY INSTRUCTIONS

a)        Thoroughly clean the external area of the drive side casing where you will be working.

   b)     Disassemble the drive side casing while carefully ensuring that the truing bushes and the screws for the latter
          (Photo I a) are not damaged or lost.

c)    Unscrew the variator lock nut on the crankshaft (Photo I b).

d)   Completely remove the entire original variator unit by sliding it off of the crankshaft.

e)   Disassemble the rear clutch unit in the kit when the spring has been provided to replace the original one (Photo 2).

f)     To fit the spring, if present in the ~Malossi kit, the tightening nut on the clutch mass-

       holder flange (Photos 3 a and 3 b) must be unscrewed and care must be taken with the thrust of the spring found under the clutch.

g)    Fit the new spring supplied in the kit (Photo 4).

h)   Reassemble the clutch unit as it was previously. Check the belt for wear and if it is not in perfect condition, we suggest that you replace it with one of our Malossi Kevlar Drive Belts. Remount the clutch unit with the belt inserted in the pulley and tighten the lock nut according to the manufacturer's instructions (Photo 5).

i)     Mount the sliders (5) on the cover (8) as shown in the Variator assembly diagram.  Ensure that they are inserted flush.

1)     Position the rollers (4) in the mobile split pulley (3) (Photo 6).

m)    Insert the cover (6) complete with sliders over the mobile split pulley with the rollers inserted (Photo 7).

n)    Insert the spacer (7), if present, on the crankshaft.

o)    Insert the hub (2) in the mobile split pulley and carefully slide the complete unit on the crankshaft, ensuring that the rollers do not come out of their guides (Photo 8).

p)    The Variator unit should be positioned flush and then position the belt on the hub.  Mount the original stationary split pulley (1) or otherwise the one supplied with the kit.  Mount the small fan and the fastening washer, if present (Photo 9).

q)    Insert the tightening bolt and tighten it with your fingers (Photo 9).

r)     Loosen the belt and tighten it in the middle in such a manner that when the crankshaft bolt is being closed, the timing belt is not caught between the pulleys, thereby imitating the packet closure of the entire ~variator unit (Photos 9 a, 9 b).

s)    The bolt on the crankshaft fastening the variator should be tightened at the torque indicated by the manufacturer.