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Idiomas disponibles
Idiomas disponibles
L - Speed control bush made of chrome-plated nickel (casehardened, tempered and ground) (TO BE LUBRICATED USING THE GREASE
SUPPLIED)
Bronze bush with self-lubricating graphite inserts (DO NOT LUBRICATE)
Self-lubricating bush made of sintered bronze (DO NOT LUBRICATE)
M - Spacer for compression spring (if included)
N - Rear "Air Speed" half-pulley: it is made of die-cast aluminum for better performance and cooling improvement
- ASSEMBLY INSTRUCTIONS -
Clean your scooter, making sure that the crankcase area on the transmission side is perfectly clean. Remove the transmission crankcase
(take care not to loose the screws and centring bushes) and then unscrew the locking nut on the speed control fitted on the crankshaft.
Extract the complete speed control unit from the crankshaft. If the kit includes the compression spring, replace the original one (having
first removed the clutch box). Take care when removing the locking nut as the spring is loaded.
Caution: we recommend replacing the original drive belt with a Polini belt.
Fit the clutch box, making sure that the belt is correctly fitted on the semi-pulley and then tighten the locking nut (check the original
manufacturer's torque tables). Pour all the grease (I) provided in the kit in the pin (H) and in the bush (L) only for pulleys with NON
self-lubricating bush (drawing 2). Insert the rollers (E) in the mobile semi-pulley (F), making sure that the part that beats in the insert is
in the opposite direction to the one of rotation of the speed control (drawing 3).
Caution: for some speed controls, the rollers have been divided in two series to get the perfect weight calibration; if this is the case,
alternate the different coloured rollers in their seats (drawing 4)
Place the disk (C) on top of the semi-pulley (F) with the disk guides (D) previously inserted in their seats and, if provided in the kit, the
spacer (B). If there are no Polini guides and disks in the kit, use the original ones; in this case, we recommend checking their state of
wear and replacing them if necessary. Taking care not to "pinch" the oil seals, lightly grease the external surface of the pin, turn the
pin and insert it (H) in the mobile semi-pulley and then fit the entire unit on the engine shaft. Caution: the rollers could slip from their
seats while doing this. If included in the box, insert the Polini compression Spring A and place the EvoSlider in the original spring lock
(pict. 11) Caution: the convex side must stay upward.
Remove any traces of oil on the mobile pulley and on the crankshaft using some thinner (or any other similar product). After placing
the belt on the hub(Caution: If the original belt is worn we suggest changing it with a Polini one), fit the original fixed semi-pulley (if
the kit contains a new one, use this), then add the rear AirSpeed half pulley (N) and the and the tab washer (if included in the kit). Ma-
nually tighten the locking bolt and then loosen the belt: hold this one in the middle so that it is not closed between the pulleys and the
drive belt when the crankshaft bolt is tightened. Check the original manufacturer's torque tables before tightening the engine shaft bolt.
Caution: All speed control kits include tested rollers to ensure max performance on original engines; you can, however, alter the
calibration of the speed control by using special rollers obtainable from our authorised dealers. You can consult our catalogue with the
complete range of rollers on www.polini.com. Most of the Polini speed controls do not require grease to lubricate the rollers.
IMPORTANT! Always check the assembling instructions of each speed control.
Caution: after fitting the speed control on the vehicle, always check that the new speed control unit is fixed correctly. Polini Motori
cannot be held liable for any alterations made by the original manufacturers.
241.601-241.605-241.616: fit the kit components as per drawing 5. Caution: the kit includes a spacer needed to increase the
pre-loading of the compression spring. You need to remove the clutch box from the speed control: be careful when removing the locking
nut as the spring is loaded. Fit the new spacer inside the shoe holder plate.
241.602: this speed control requires grease to lubricate the rollers (like the original one). Use the original grease cap and O-ring; use
the type and quantity of grease recommended by the manufacturer. On some versions, ovalize the fixing holes to fit the grease cap.
241.608: fit the kit components as per drawings 4 - 7 or 8.
241.609: fit the kit components as per drawings 4 - 5 - 6. Caution: the kit includes a spacer needed to increase the pre-loading of
the compression spring. You need to remove the clutch box from the speed control: be careful when removing the locking nut as the
spring is loaded. Fit the new shim inside the shoe holder plate. For 125 cc engines use the 13,2 g. yellow rollers and the 10,4 g light
blue ones. For 150 cc engines use the 13,2 g. yellow rollers and the 14,7 g. red ones.
241.618: to assemble the new speed control, remove all the body parts and the components that may make it difficult to remove the
original speed control. Loosen the screw of the rear connection of the exhaust system and disassemble the transmission cover.
Using the two hexagonal-head M6 screws which fix the variator cover case, enlarge the pulleys of the rear speed control to keep tension
away from the transmission chain (figure 9); unscrew the crankshaft nut and remove the complete speed control. To assemble this kit,
use the gaskets, rollers plate and original grease cap. Check the wear of the guides and, if necessary, replace them with original spare
parts. This speed control requires grease to lubricate the rollers (like the original one). Use the original grease cap and O-ring; use the
type and quantity of grease recommended by the manufacturer. On some versions, ovalize the fixing holes to fit the grease cap.
Attention: torque wrench setting of the crankshaft nut: 16 Kgf.m - 160 N.m
241.627: after removing all the body parts and the components that may make it difficult to remove the original speed control, disas-
semble the transmission cover and unscrew the speed control locking nut on the crankshaft; remove the belt and the speed control from
the crankcase. To assemble this kit, use the original guides and roller cover; check the wear of the guides and, if necessary, replace them.
241.630: to assemble the new speed control, remove all the body parts and the components that may make it difficult to remove the
original speed control; loosen the screw of the rear connection of the exhaust system and disassemble the transmission cover.
Using the two hexagonal M6 screws which fix the speed control cover case, enlarge the pulleys of the rear speed control to keep tension
away from the transmission chain (figure 9); unscrew the crankshaft nut and remove the complete speed control. To assemble this kit,
use the gasket, rollers plate and grease cap. Check the wear of the guides and, if necessary, replace them with original spare parts.
For original engines use the 16,2 g red rollers. For the engines with special exhaust systems, use the 14,1 yellow ones. To achieve an
intermediate calibration, alternate four 16,2 g. red rollers and four 14,1 g. yellow ones.
Attention: torque wrench setting of the crankshaft nut: 16 Kgf.m - 160 N.m
241.636: For 400 cc Piaggio engines use the 12 gr. rollers. For 500 cc Piaggio engines use the 14 gr. rollers.
241.652-241.668-241.684-241.685: to assemble the new speed control, remove all the body parts and the components that
may make it difficult to remove the original speed control; loosen the screw of the rear connection of the exhaust system and disassem-
ble the transmission cover. Using the two hexagonal M6 screws which fix the speed control cover case, enlarge the pulleys of the rear
speed control to keep tension away from the transmission chain (figure 9); unscrew the crankshaft nut and remove the complete speed
control. Attention: torque wrench setting of the crankshaft nut: 16 Kgf.m – 160 N.m. In the package you find 2 groups of rollers of
different weight. Polini Motori advises the assembly of the lighter rollers (7,5gr). After assembling these rollers the engine will work
at 200/300 rpm over the maximum power for the first 200/300 kms. When the running-in is over the engine will set and the engine
efficiency will be linear and constant in the time. Caution! We remind you that the self-lubricating bush with graphite inserts must NOT
be lubricated with grease. If included, fit the Polini compression spring with the EvoSlider (pict.12)
241.663: remove the variator cover case unscrewing the driven pulley nut too. Keep the original variator off and fit the Polini one
(See fig. 1, use C plate and the ORIGINAL D guides). Attention: check the wear condition of the guides and change them if necessary.
DO NOT USE GREASE. THE LUBRICATION IS GRANTED BY THE GRAPHITE INSIDE THE BUSH. Place the belt in the driven pulley using the
Piaggio tool. Assemble the variator being careful to eliminate all the dirt or grease present between the pulleys or inside of them and
re-assemble all the parts. IMPORTANT: DRIVING PULLEY TIGHTENING TORQUE VALUE 250/270 N.M
DRIVEN PULLEY TIGHTENING TORQUE VALUE 150/180 N.M
241.664: fit the variator washer as indicated in drawing 10.
- maXI HI-sPEEd VarIator -
To assembly the drive half pulley please read the following instructions:
1- Insert the "J" spring in the position indicated in the pict. 14.
2- Carefully fill in the "K" + "W" housings with the special grease for high temperature you find in the packaging, maintaining the
spring in its housing and placed on the rollers side as shown in pict. 14.
3- Place the "X" plastic plug supplied inside the bush for all its length (pict. 15).
4- Insert the "Y" pin behind the plastic plug and push it till it comes out the opposite side. The plastic plug allows the "J" internal spring
enlargement and allow the pin fitting in. During this operation be sure that bush and plastic plug lean each other, eventually press the
opposite side of the inserting zone (Pict. 16).
5- After these operations have been executed, the "X" plastic plug is not need anymore and it can be used only if you have to fit the pin
again.
6- ATTENTION: follow the abovementioned instructions because in case of wrong pin fitting, the grease will be ejected from its
housings.
SERVICING - The Maxi Speed Control needs to be checked together with the rest of the drive mechanism every 2000 - 3000 km; top
up the grease in the pin (if included) and its bush (see fig. 2). Replace any worn parts.
- See our catalogues or our web-site: www.polini.com -
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