Polini HI-SPEED Instrucciones De Montaje página 3

HI-sPEEd - suPEr sPEEd
suPEr sPEEd EVoLutIon VarIators
Polini Motori, thanks to its experience in setting up scooter transmission parts, has now projected
the best variators never manufactured to date. Made from the best quality materials and with the
most advanced working project, they let an uniform pick-up and constant engine performance.
They allow to obtain the maximum torque faster compared to other variators and the pulley
features a more balanced movement.
TECHNICAL FEATURES (drawing 1)
A - Spacer (if included)
B - Steel chromed rollers disk guide
C - Disk guides
D - Mobile semi-pulley: made from a special die-cast silicon alloy, diamond finishing
E - Rollers: calibrated weight, with nylon coating. They ensure a great wear resistance.
F - Speed control bush made from self-lubricating sintered bronze
- Steel bush with patented lubrication system (pictures 11-12)
G - Variator pin made from hardened and tempered and lapped chrome-plated steel.
H - Spacer (if included)
I - Specific steel clutch springs (if included)
L - Compression spring with Evo Slider (if included)
ASSEMBLY INSTRUCTIONS FOR THE HI-SPEED AND SUPER SPEED
Clean your scooter, making sure that the crankcase area on the drive side is perfectly cleaned. Re-
move the case (take care not to lose the screws and centering bushes) and then undo the locking
nut on the speed control fitted on the engine shaft. Extract the complete speed control unit from
the engine shaft. Caution: we recommend replacing the original drive belt with a Polini belt if
there are signs of wear. Insert the rollers (E) in the mobile semi-pulley (D), making sure that the
part that beats in the insert is in the opposite direction with respect to the rotation of the speed
control (drawing 2). The variator package might include two rollers series. You can reach great
tuning up mixing the two series with the condition not to vary the uniformity of the axial thrust
(drawing 3). Place the disk (B) on the top of the semi-pulley with the disk guides (C) already in
their seats (drawing 4) and, if provided in the kit, the spacer (A). Turn and insert the piston pin
(G) in the mobile semi-pulley (D) and then fit the entire unit on the engine crankshaft.
Caution: the rollers could slip from their seats while doing this.
If provided with the kit, fit the Polini compression spring and the EvoSlider in the original spring
stay (pict. 1). Caution: keep the convex side upwards
Caution: we suggest replacing the worn belt with a Polini one.
Caution: for the Minarelli engine only a spacer (H) is provided to replace the original one.
Before fitting the speed control unit, remove any traces of oil on the driven- pulley and engine
ENGLISH
shaft using some thinner (or similar product). After placing the belt on the hub, assemble the
original fixed semi-pulley again (if the kit contains a new one, use this), then add the fan and
the tab washer (if included in the kit). Check the original manufacturer's torque tables before
tightening the engine shaft bolt. When the kit includes the clutch springs change them with the
original ones; then unscrew the clutch bell and the clutch being careful to the spring axial thrust.
Once the springs have been changed assemble all the parts again.
Fit the case being careful not to damage the gasket. In order to check that the assembly has been
done correctly, place the bike on the stand, start up the engine, and accelerate gradually to check
that the variator and the belt work perfectly. ATTENTION: the assembly of the variator is the
same as the original one with the exception of the models below mentioned.
Caution. The plastic rollers of the Polini variator do not need any lubrication; it is therefore
unnecessary to put on any cover to hold in the grease.
241.301 For Yamaha-Mbk only. For this special variator we suggest replacing the original clutch
springs with the Polini one included in the kit.
241.460-241.361-241.561 During the assembly, place the spacer as shown in pict. 7.
Important – for 241.460 only: replace the original nut and washer placed at the end of the
crankshaft.
241.470 During the assembly place the spacers as shown in pict. 8.
241.310-241.530 The plastic cover is to be pressed on the variator pulley, fitting it into the
special guide; for removal it should be levered off with a screwdriver.
241.520 See picture 9.
This new SUPER SPEED variator has been designed to be used on engine fitted with Polini evo-
lution cylinder kit. It grants a great belt excursion in order to supply high speed even with short
gears. It is possible to fit the variator with the original belt, with the Polini belt or with the Polini
Kevlar belt for race use; in this way you improve the range coupling the tuned-up Polini Speed
Drive for Minarelli and Piaggio engine. Follow the assembly diagrams and the correspondent
belt types. (Pict. 5). The shims supplied with the kit may have some burring: eliminate it using a
scraper or abrasive paper.
MINARELLI ENGINE: CAUTION! To fit the variator remove the electric starter parts placed on
the crankcase.
1- Insert the "A" spring in the position indicated in the pict. 11
2- Carefully fill in the "B" + "C" housings with the special grease for high temperature you find
3- Place the "D" plastic plug supplied inside the bush for all its length. (pict. 12)
ASSEMBLY INSTRUCTIONS FOR THE SUPER SPEED EVOLUTION VARIATOR
ASSEMBLY INSTRUCTIONS FOR THE VARIATORS WITH PATENTED
LUBRICATION SYSTEM
in the packaging, maintaining the spring in its housing and placed on the rollers side as shown
in pict. 11