PRESS INFORMATION.indd

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Crankcase
Malossi engines were born to amaze and they do it in a broad sense, from the aesthetic side to their unprecedented versatility!
The two engines mark a turning point in the history of engines for hyper sporty scooters.
All the adopted technical solutions are part of a revolutionary project, capable of satisfying the most demanding customers.
Every detail has been designed, developed and implemented to make of our engines the kings of scooter engines.
The new crankcases have been designed and manufactured at Malossi headquarters in Calderara di Reno, one of the most advanced research,
development and production centers of special parts for engines and scooters.
These crankcases, which can be used on all scooters that fit a Piaggio 50cc engine as original equipment, have been designed and set up in
order to:
• fit both drum brake and disc brake.
• Replace the original engine both with short and long wheelbase. The position of the shock absorber fixing has been designed to satisfy both
options.
• Install both cylinders with stud bolts and cylinders with flange fixing.
• Use an electric cooling pump to eliminate the power consumption of the traditional mechanical water pump.
• Eliminate the automatic mixer
• Install the vacuum fuel pump
• Install the new bigger reed valve, designed using sophisticated programs of 3D fluid-dynamics simulation
• Install all the currently available Malossi products
For our most demanding customers we have developed a crankcase version which
uses only cylinders with flange fixing and crankcase with such dimensions as to
allow the installation of Big Bore crankshafts without any additional intervention.
Of course, this version as well keeps all the versatility features of the basic
version.
Build a new engine, customize your racing scooter, choose from the Malossi
catalogue the most prestigious parts! We will be ready to provide whatever
technical assistance may be needed!
Technical features:
• Crankcase pair, die-cast material in aluminum silicon alloy with high mechanical
resistance.
• Crankcases inclusive of silent block 5,250 Kg.
• Crankshaft - clutch shaft wheelbase 270 mm.
• Bolt holes wheelbase 48 x 48.
• Crankshaft bearings 20 x 47 x 14.
• Oil seals FKM plus PTFE.
• Reed valve VL 18.
• Intake manifold X360.
• Cylinder stud bolts material: steel 8.8 UNI EN20898/1.
• Fluid connector.
• Wheel axle bearing 20 x 47 x 14.
• Roller gear cover size 16 x 22 x 12.
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COMPLETE ENGINE MHR C-one
5715844
Available from March 2014
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Transfer ports perfectly connected to Malossi
MHR Team 7-port cylinder kits.
Cylinder housing boring Ø 57.
Installation of cylinders
with stud bolts.
Installation of Malossi cylinders with flange
fixing available in the second half of 2014.
Set up for Malossi roller crankcase 2514603
MHR / original.
Set up for starter crankcase cover
Gilera Runner 50 2T.
val of automatic mixer.
Removal
Oversized roller cage Ø 16 x 22 x 12.
6
Oversized mono petal reed
valve Malossi VL18.
COMPLETE ENGINE MHR C-one
Crankcase boring Ø 73.
Bearing housing Ø 47.
Vacuum fuel pump set up.
Brake caliper installation set up.
Inner-rotor ignition fixing holes.
Brake shoes installation set up.
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Force Master 3 CDI (injection)
Product description
Force Master 3 is the final stage of the technological evolution of Malossi CDIs, aimed at adjusting carburetion. It allows a further performance increase thanks to a thorough revision of
both hardware and software. The integration of the lambda sensor can allow Malossi engineers dynamic management of the air/fuel ratio where the lambda control is active. Therefore,
it is possible to differentiate the air/fuel ratio between the idle and transition zones, in order to obtain a faster engine response during transitions. To increase the accuracy of the reading
of the throttle position sensor, a differential circuit has been used to improve the CMRR (Common Mode Rejection Ratio), which normally “pollute” the positional demand signal. Besides
a more precise reading of the signal, the use of such a configuration allows a more rapid interpretation of the actual throttle position thanks to a reduction of filters normally used in a
classical circuit architecture. The use of a new microprocessor with a high calculation capacity and the introduction of new software strategies have created an optimal synergistic effect
with the hardware. Particular attention has been given to improving the user interface by introducing a graphic display that shows the main functional parameters of the device.
The following parameters are displayed:
• Position of correction trim switches
• Selected map
• Diagnostics status
• Firmware version
• Throttle calibration
• System status
The number of maps is increased from the 4, available on Force Master 2, to the current 8 maps.
This allows a greater number of tuning stages for each model. The strength of the entire Force Master series is the synergy between the various mechanical components Malossi that
can be used to increase the performance of the vehicle, and the fine tuning made by our technicians. The study of the different tuning stages and the dedicated maps guarantee the user
a perfect reproduction of the performance achieved on the test benches.
The main structure is inherited from the previous model, Force Master 2, which has allowed to obtain great satisfactions up to now.
The main features are the following:
• Carburetion adjustment +-250%
• Fuel correction levels 8 * 20 break point
• Fuel management during engine warm up phase
• Programmable acceleration pump
• Extended operation over rev limiter
• Where possible, reading engine parameter via K-Line KWP2000
• User carburetion compensation, by means of three external trimmer switches, ± 20% at min/average/max
• Shielded from electromagnetic disturbances from the vehicle
• Oil and fuel resistant cables with operating temperatures -20 to +150 °C
Force Master 3 is equipped with a Can bus, which will allow future expansion features like:
• Auto tuning with an external linear lambda sensor
• Module to control ignition timing
• Ability to update maps, via communication tools
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Selected map.
TPS calibration.
P
Position of the carburetion
c
correction
s
switches LOW RPM.
Tachometer.
TPS status.
5515732 BMW
C Sport 600 euro 4
C GT 650 euro 4
5515730 YAMAHA
T MAX 530 2012 (J409E)
FORCE MASTER 3
CDI status.
P
Position of the carburetion
c
correction
s
switches HIGH RPM.
Position of the carburetion
correction
switches MID RPM.
Technical features:
• Fuel adjustment
• ± 20% al LOW / HIGH / MID
• RPM limiter : + 1000 RPM
• 8 different maps
• Lambda emulator
• Temperature range = -20°C +80°C
• Minimum working voltage = +7V
• Maximum working voltage = +16V
• Average current consumption <- 200mA
• Environmental protection = IP65
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NEW OVER RANGE MHR ALUMINUM MALOSSI:
THE RED FURY
Kit Over Range MHR Aluminum Malossi: High Performance Scooter Transmission
The transmission is one of the key components in a scooter. The kit Malossi MHR Aluminum Over Range is
designed to improve efficiency and engine power, ensuring longevity and tuning flexibility.
The centrepiece of the new kit Malossi variator transmission remains the Multivar, in constant evolution, which
is accompanied by two sets of rollers to adjust the operation of the transmission according to your needs. With
the wide range of variator rollers available in our catalogue, the set-ups are virtually endless.
The variator’s sliding roller ramps have been redesigned to maximize the transmission’s performance.
Malossi, always searching for perfection, has also revised the hub, in addition to chrome plating and grinding,
it is subjected to a vibratory finishing process, one of the most recent and avant-garde techniques, resulting in
a mirror like finish.
For the first time, the variator Malossi MHR Aluminum Multivar is supplied with the fixed half pulley Ventilvar.
On the other side of the crankcase there is the new Torque Driver - Malossi Aluminium Rear Pulley System MHR
Aluminum, now in aluminium for lightness and strength increase. The pulley is riveted to the hubs for maximum
strength and to reduce the tolerance between the hub and the bushing. The surface roughness is just Ra 0.4.
The Torque Driver is made of aluminium, a material with exceptional heat dissipation, and was subjected to a
micro perforation process to increase transmission belt grip and to keep it clean and efficient, expelling from
the holes any heat created contaminants.
The drive belt –Malossi X K Belt, based on the technology developed for the maxi-scooter belts, has an extremely
small cross section and intended for two-stroke scooter racing, guaranteeing grip and consistent performance.
The revolutionary scooter transmission kit - Over Range Malossi MHR Aluminum will soon be available at all
Malossi dealers and online at Malossi Store.
6115780
10
6115781 – 6115821
Table of applications
APRILIA
BENELLI
BETA
DERBI
GILERA
ITALJET
SCOOTER
AMICO 50 2T
6115821
BOOSTER 50 2T euro 0-1-2
6115821
AREA 51 50 2T LC
GULLIVER 50 2T LC
6115821
BOOSTER NG 50 2T euro 0-1-2
6115821
6115821
BOOSTER NAKED 50 2T euro 2 (A137E)
6115821
MOJITO CUSTOM 50 2T
6115781
BOOSTER ROCKET 50 2T euro 0-1-2
6115821
RALLY 50 2T / 2T LC (MINARELLI)
6115821
BOOSTER SPIRIT 50 2T euro 0-1
6115821
SR 50 2T 1994->
6115821
FLIPPER 50 2T
6115821
SR (carb.) 50 2T LC 2004 (PIAGGIO)
6115781
MACH G 50 2T / 2T LC
6115821
SR MOTARD 50 2T euro 2
6115781
NITRO 50 2T LC
6115821
SR NETSCAPER 50 2T LC (MINARELLI)
6115821
OVETTO 50 2T
6115821
SR R (carb.) 50 2T LC (PIAGGIO)
6115781
STUNT 50 2T euro 0-1-2
6115821
SR RACING 50 2T LC (MINARELLI)
6115821
DIESIS 50 2T
6115781
SR REPLICA 50 2T LC
6115821
FLY 50 2T
6115781
SR STEALTH 50 2T LC (MINARELLI)
6115821
FREE 50 2T 2001->
6115781
SR WWW 50 2T
6115821
NRG EXTREME 50 2T / 2T LC
6115781
491 GT 50 2T (MINARELLI)
6115821
NRG MC2 50 2T LC 1998->
6115781
491 SPORT 50 2T LC (MINARELLI)
6115821
NRG MC3 DD 50 2T LC
6115781
K2 50 2T / 2T LC
6115821
NRG MC3 DT 50 2T
6115781
NAKED 50 2T
6115821
NRG Power DD 50 2T LC
6115781
ARK 50 2T / 2T LC
6115821
NRG Power DT 50 2T (C453M)
6115781
EIKON 50 2T LC
6115821
TYPHOON 50 2T 2007->2010
6115781
QUADRA 50 2T
6115821
ZIP 50 2T 2000
6115780
ATLANTIS - BULLET 50 2T 2003->
6115781
ZIP SP 50 2T LC 2001->
6115780
GP1 50 2T LC
6115781
ET2 50 2T 2000
6115780
GP1 OPEN 50 2T LC
6115781
LX 50 2T
6115780
GP1 REVOLUTION 50 2T LC
6115781
S 50 2T euro 2 (C381M)
6115780
ICE 50 2T
6115781
AEROX 50 2T LC euro 0-1-2
6115821
RUNNER 50 2T LC
6115781
BW'S 50 2T euro 0-1-2
6115821
RUNNER SP 50 2T LC <-2005
6115781
BW'S NG 50 2T euro 0-1-2
6115821
RUNNER SP (carb.) 50 2T LC 2006-> (C451M) 6115781
BW'S Original/Naked 50 2T euro 2 2010 (A137E)
6115821
STALKER 50 2T
6115781
JOG R 50 2T
6115821
TYPHOON X 50 2T
6115781
JOGRR 50 2T LC euro 2
6115821
DRAGSTER 50 2T LC
6115821
NEO'S 50 2T
6115821
JET SET 50 2T
6115781
SLIDER 50 2T
6115821
MBK
PIAGGIO
VESPA
YAMAHA
6115821
SPY 50 2T
6115821
F12 DIGIT KAT-PHANTOM 50 2T LC / LC euro 2
6115821
WHY 50 2T
6115821
F12 R LC 50 2T LC euro 2
6115821
ZUMA 50 2T
6115821
F15 FIREFOX 50 2T LC
6115821
MALAGUTI F12-PHANTOM 50 2T / 2T LC
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RED FURY
SCOOTER
Table spare parts
6115780
OVER RANGE MHR ALUMINUM - PIAGGIO 2000 ENGINES (SHORT CRANKCASE)
06 9854E
19 9057B
1911195B
2011754
23 8272B
2514311B
5115644
6114308
6114309
6114582
6115104
66 8274B
7611882B
7615375B
2 O-RING Ø 39x1,5 mm
NUT M 28x1x4
SHIM Ø 18x12
FIXED PULLEY OVERHAUL KIT
PIVOT PIN for TORQUE DRIVER
SPRING GUIDE Ø 60-43
VARIATOR MULTIVAR 2000 MHR ALUMINUM SCOOTER (PIAGGIO)
FIXED PULLEY MHR ALUMINUM
TORQUE DRIVER MHR ALUMINUM
REAR PULLEY SYSTEM MHR ALUMINUM
X K belt MHR ALUMINUM for OVER RANGE MHR ALUMINUM
2 OIL-SEAL Ø 34x39x3
MRG grease tube - lubricating grease for TORQUE DRIVER
MHR grease tube - lubricating grease for MULTIVAR
6115781
OVER RANGE MHR ALUMINUM - PIAGGIO 2000 ENGINES (LONG CRANKCASE)
06 9854E
19 9057B
1911195B
2011754
23 8272B
2514311B
5115644
6114308
6114309
6114582
6115668
66 8274B
7611882B
7615375B
2 O-RING Ø 39x1,5 mm
NUT M 28x1x4
SHIM Ø 18x12
FIXED PULLEY OVERHAUL KIT
PIVOT PIN for TORQUE DRIVER
SPRING GUIDE Ø 60-43
VARIATOR MULTIVAR 2000 MHR ALUMINUM SCOOTER (PIAGGIO)
FIXED PULLEY MHR ALUMINUM
TORQUE DRIVER MHR ALUMINUM
REAR PULLEY SYSTEM MHR ALUMINUM
X K belt MHR ALUMINUM for OVER RANGE MHR ALUMINUM
2 OIL-SEAL Ø 34x39x3
MRG grease tube - lubricating grease for TORQUE DRIVER
MHR grease tube - lubricating grease for MULTIVAR
6115821
OVER RANGE MHR ALUMINUM - YAMAHA / MINARELLI ENGINES
06 9854E
0812036
19 9057B
1911195B
2011754
23 8272B
2514311B
5115823
6114590
6114595
6114596
6115822
66 8274B
7611882B
7615375B
2 O-RING Ø 39x1,5 mm
SPACERS KIT for REAR PULLEY SYSTEM
NUT M 28x1x4
SHIM Ø 18x12
FIXED PULLEY OVERHAUL KIT
PIVOT PIN for TORQUE DRIVER
SPRING GUIDE Ø 60-43
VARIATOR MULTIVAR 2000 MHR ALUMINUM YAMAHA / MINARELLI
FIXED PULLEY MHR ALUMINUM
TORQUE DRIVER MHR ALUMINUM
REAR PULLEY SYSTEM MHR ALUMINUM
X K belt MHR ALUMINUM for OVER RANGE MHR ALUMINUM
2 OIL-SEAL Ø 34x39x3
MRG grease tube - lubricating grease for TORQUE DRIVER
MHR grease tube - lubricating grease for MULTIVAR
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RED FURY
Attention! for YAMAHA / MINARELLI ENGINES
If your vehicle is equipped with Malossi crankshaft (art. 5312810 - 5313275 - 5314548),
must replace original fi xed cover and hub with those included into this kit, in order to install
Multivar 2000 MHR Aluminum (art. 5115823).
FIXED COVER / HUB KIT
FOR MALOSSI CRANKSHAFT.
2015832
1
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VESPower Ignitions
5515475
5515610
5515660
5515684
5515702
The new range of complete ignitions for vintage gear Vespa was born
born.
In order to allow an easy and perfect installation, a specificc version
for each model has been studied.
The new ignition range features:
- lightened flywheel (weight 1,2 kg) with moment of inertiaa equal
to 28 Kg/cm² (see attached chart). It is made from forgedd with
external set up for additional masses (not included into the
he kit)
- 12 V (90 Watt ) 4-pole stator with output for battery charging
ging
condary
- red colored plastic fan with advanced booster cooling secondary
fins (optimized fan profile and distribution absorption)
- wiring dedicated to each specific application
- integrated coil/ control unit
- voltage regulator
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Crankshaft
cone
Ø
Static
weight
kg.
Moment
of inertia
Kg/cm2
Note
19
1,2
28
You need to replace all the lamps
(from 6 to 12 V), respecting original
power expressed in Watts.
COSA 125 - 150 - 200 2T
5515610 (*) PX 125 - 150 euro 0-1-2-3
PX E 200 2T
20
1,2
28
5515660
ET3 125
20
1,2
28
You need to replace all the lamps
(from 6 to 12 V), respecting original
power expressed in Watts.
5515684
SPECIAL 50
19
1,2
28
You need to replace all the lamps
(from 6 to 12 V), respecting original
power expressed in Watts.
COSA 125 - 150 - 200 2T
5515702 (*) PX 125 - 150 euro 0-1-2-3
PX E 200 2T
20
0,9
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Ignition with further lightened inertia
flywheel is available, void of external
set up for additional masses.
Code
5515475
Applications
ET3 125
(*) NB: For versions without battery optional wiring is available art. 5515703
battery charger kit,consisting of wires and voltage regulator.
As optional you can get the additional flywheel masses, which allow
w
to adapt the ignition to the own vehicle according to its set-up, thuss
further increasing the moment of inertia.
You can choose between two versions with different weight andd
moment of inertia:
Flywheel masses
Code
Applications
Dimensions
Static weight
gr.
(including screws)
Moment
of inertia
Kg/cm2
1715715
For ALL VESPower
EXCEPT art. 5515702
Ø 144x105x18
824
34
1715716
For ALL VESPower
EXCEPT art. 5515702
Ø 134x105x18
420
19
15
VESPA [gears]
VESPower Ignitions