mounting guide

MOUNTING GUIDE
ENG
MS-INSTRUC-02ENG
11/2014
CYLINDER MXS GP 90
FOR:
DERBI EURO 2
Ref.: MXSGP002
DERBI EURO 3
Ref.: MXSGP003
MINARELLI AM6
Ref.: MXSGP006
MINARELLI HORIZ . LC
Ref.: MXSGP008
MAXISCOOT - B.P. 50040 - F-57601 - Forbach Cedex
01 MOUNTING GUIDE : CYLINDER GP90 E INTRODUCTION / MOTOR CONFIGURATION
THE INSTALLATION INSTRUCTIONS MUST BE READ
CAREFULLY TO AVOID
ENGINE DAMAGE.
1. INTRODUCTION
Thank you for purchasing the MXS Racing GP90 cylinder and for
the confidence you thereby place in our company.
The GP90 is the latest development of the MXS team, and the
result of two years of intensive work. The patented cylinder mounting replaces the traditional studs by socket screws and aluminum
sealing plugs at the lower part of the cylinder. This system facilitates
the design of new transfer and exhaust port layouts that a
traditional construction would not allow of. This results in a
higher peak power and torque!
WARRANTY
The warranty of the MXS RACING cylinder kit includes initial
manufacturing defects that can be observed prior to installation. The
warranty does not apply to damages caused by natural wear, external influences (faulty assembly or disassembly, faulty maintenance,
improper use...) or by a modification of the product not intended or
specified by the dealer. For more information, contact us at info@
maxiscoot.com.
1.1 PREREQUISITES
To ensure the full potential and durability of the GP90 MXS cylinder,
the following requirements have to be met:
TABLE OF CONTENTS
3. Scope of delivery
Refers exclusively to Derbi Euro2 / 3 and AM6 engines
Euro 2 + 3, AM6
SYMBOL SCOOTER :
Refers exclusively to Minarelli horizontal engines
Min horiz. LC
2. RECOMMENDED ENGINE CONFIGURATION
4. Milling the engine case
6-7
8
9
5.4 Installation of the cylinder head / combustion chamber
11
5.5 Position of cylinder head bolts
9. Running in the engine
CVT GEARBOX: Overrange kit, Malossi, Stage6 or Polini
RECOMMENDED TRANSMISSION: Primary 14/42,
Secondary 16/41 (Street)
Secondary 14/41 (Run)
4-5
10
SPARK PLUG: NGK 105
IGNITION: Stage6 R / T (PVL) or Bidalot (PVL)
SCOOTER :
3
5.3 Installing the sealing plug
6. Water cooling
TRANSMISSION: Bidalot
CLUTCH: Minimum 5-disc clutch
3
3
5. Installing the MXS GP90 cylinder kit
5.1 Mounting the cylinder 5.2 Squish clearance
CRANKSHAFT: MXS Racing
EXHAUST: 90cc MXS Racing
CARBURETOR: The minimum carburetor size is 30mm, to exploit full
potential, a bore size of 38mm is recommended.
GEARED MOPED:
Page
1. Introduction
1.1 Prerequisites
2. Recommended engine configuration
SYMBOL GEARED MOPED :
CHECK OUT ALL THE MXS GP 90
PRODUCTS ON THE LAST PAGE
7. Ignition
8. Fuel 12
13
13
13
13
10. Maintenance & Service
13
12. Portmap
14
11. Tuning13
13. Replacement parts
15
SCOPE OF DELIVERY
02 MOUNTING GUIDE : CYLINDER GP90
3. SCOPE OF DELIVERY
Individual parts cylinder head:
1.1
1.2
1.3
1.4
Cylinder head cover
O-ring cylinder head cover
Water deflector
O-ring combustion chamber to cylinder head cover
1.5
1.6
1.7
1.8
Combustion chamber
O-ring combustion
chamber to cylinder
Vent connections
Washer Ø 6 mm
1.9
1.10
1.11
1.12
4x
EXPLODED VIEW CYLINDER HEAD
4x
Washer Ø 5mm
4x
4x
8x
4x
Screws M5 x 25 mm
Screws M6 x 20 mm
Screws M6 x 25 mm
2.1
2.2
2.3
2.4
Piston
Piston ring
Gudgeon pin
Gudgeon pin clip
3.2
3.3
3.4
Individual parts piston :
2x
EXPLODED VIEW PISTON
Individual parts cylinder :
3.1
Min horiz. LC
2x
3x
Cylinder MXS GP 90cc
Base gasket paper
0.2 mm
Base gasket aluminum
0.1 mm
Spacer cylinder base
5mm
3.5
3.6
3.7
3.8
Euro 2 + 3, AM6
2x
Exhaust flange gasket
Water supply
Washer Ø 24 mm
Screws M7 x 35 mm
3.9
3.10
3.11
3.12
Min horiz. LC
EXPLODED VIEW CYLINDER
2x
2x
8x
4x
Screws M7 x 30 mm
Screws M7 x 25 mm
O-rings sealing plugs
Centering pin sealing
plugs
3.13
3.14
3.15
3.16
Sealing plug front left
Sealing plug right front
Sealing plug rear left
Sealing plug back right
03 MOUNTING GUIDE : CYLINDER GP90
4. MILLING THE ENGINE CASE
MILLING THE ENGINE CASE
Diagram 4.1a
1. T
o avoid irreparable damages caused by an extreme performance increase, engine block, gearbox and all bearings must
be in perfect condition.
ø 77.3 mm
FOR SCOOTER :
2. To allow the installation in scooter engines, the cylinder base
and the crankcase have to be milled by a professional mechanic to make everything fit. (Diagram 4.1a + 4.1b)
+ 0.2mm
Min horiz. LC
FOR GEAR SHIFT :
4.3b)
4. Once the milling is completed, all bearings, oil seals and gaskets have to be replaced. We recommend to use new gearbox
bearings and to replace damaged gears and gear pairs with
new parts.
Milling scheme crankcase
(only for Min. horiz. LC)
Diagram 4.1b
Min horiz. LC
Ø 58
5. After milling the entire engine case has to be cleaned meticulously!
+ 0.1mm
2. In Derbi engines the cylinder base seat of the engine case has
to be extended by 2mm. (Diagram 4.2a + 4.2b)
3. All engines require an enlarged conrod recess (Diagram 4.3a +
Milling scheme engine case (cylinder)
(only for Min. horiz. LC)
Diagram 4.2a
Diagram 4.2b
Euro 2 + 3
Euro 2 + 3
m
2m
View of millings engine case
Detailed view
Diagram 4.3a
Diagram 4.3b
(only for Euro 2 + 3)
(only for Euro 2 + 3)
Min horiz. LC
Euro 2 + 3, AM6
Min horiz. LC
Depth
3 mm
Width
4 mm
Milling scheme conrod recess
(for Euro 2 + 3, AM6, Min. horiz. LC)
Detailed view
(for Euro 2 + 3, AM6, Min. horiz. LC)
Euro 2 + 3, AM6
CYLINDER ASSEMBLY
04 MOUNTING GUIDE : CYLINDER GP90
5. INSTALL ING THE CYLINDER
Diagram 5.1a
CUT
5.1 MOUNTING THE CYLINDER
Euro 2 + 3, AM6
Once the milling is completed, the engine is thoroughly cleaned
and equipped with new bearings and the MXS GP crankshaft is
installed, we proceed with the mounting of the cylinder:
30
FOR SCOOTERS :
35
1. Lubricate the needle bearing and install the piston.
2. Lubricate the cylinder bore.
3. Use the 0.2mm paper gasket.
4. O
nly for Nitro scooters: Use the 5mm cylinder base spacer and
apply silicone sealant on both sides.
5. Position cylinder on the engine case.
6. Tighten the screws M7 with a torque of 20Nm. (Diagram 5.1a + b)
3.9
3.8
Sectional drawing of the cylinder with indication of screw positions
(only for Euro 2 + 3, AM6)
Diagram 5.1b
CUT
Min horiz. LC
Parts used :
3.2
3.3
3.4
Min horz. LC
Base gasket paper
0.2 mm
Base gasket aluminum
0.1 mm
Spacer cylinder base
5mm
3.8
3.9
3.10
Euro 2 + 3, AM6
2x
20 Nm
Screws M7 x 35 mm
2x
20 Nm
Screws M7 x 30 mm
2x
3.10
20 Nm
Screws M7 x 25 mm
3.9
Sectional drawing of the cylinder with indication of screw positions
(only for Min. horiz. LC)
5.2 SQUISH CLEARANCE
1. Mount the cylinder head (without seals) and tighten the M6
screws (8pcs) with a torque of 12Nm.
2. Use 0.8mm tin-solder to measure the squish clearance. It needs
to be 0.55mm. Use the paper joints to regulate the squish if
needed.
If you do not know how this is done: please consult
the online pdf tutorial http://www.maxiscoot.com/magazine/tutoriaux-fiche-de-montage with the
help of an online translation.
Diagram 5.2
CUT
0.55 mm
Sectional drawing squish clearance
30
25
Min horz. LC
05 MOUNTING GUIDE : CYLINDER GP90
CYLINDER ASSEMBLY
Diagram 5.3b
56.70
To avoid irreparable damages to the engine, caused by coolant, the installation of the
sealing plugs has to be executed with utmost
care! Deburr the drill holes if necessary!
3.12
1.4
3.13
5.3. MOUNTING THE SEALING PLUGS
1. O
nce the squish clearance has been determined, remove the
cylinder head and start installing the plugs.
2. Attention! Each plug has an allocated position (see diagram 5.3b).
3. Locate the respective positions of the sealing plugs and proceed with the installation of their o-rings.
4. Once mounted, a sufficient amount of silicone sealant has to
be applied on the plugs below the o-rings (see diagram 5.3a). Now
you can insert the sealing plugs.
5. After inserting the plugs, all silicone residues have to be removed from the cylinder.
6. Mount the cylinder head and all its gaskets.
56.70
3.12
1.4
3.14
3.16
3.15
61.70
3.12
5.4 INSTALLING THE CYLINDER HEAD COVER
AND COMBUSTION CHAMBER
1.4
61.70
3.12
Diagram 5.3a
1.4
2. When inserting the combustion chamber, pay attention to the recess
of its anti rotation lock. (Diagram 5.4b)
1. Make sure the water deflector is mounted correctly (Diagram 5.4a)
Diagram 5.4a
Diagram 5.4b
1.3
1.1
1.1
Position water deflector
Position combustion chamber
Parts used :
1.1
1.2
1.3
1.4
1.5
1.6
Cylinder head cover
O-ring cylinder head cover
Water deflector
O-ring combustion chamber to cylinder head cover
Combustion chamber
O-ring combustion
chamber to cylinder
3.11
3.12
3.13
3.14
3.15
3.16
Sealing plug front left
Sealing plug right front
Sealing plug rear left
Sealing plug back right
8x
4x
O-rings sealing plugs
Centering pin sealing
plugs
1.5
CYLINDER ASSEMBLY
06 MOUNTING GUIDE : CYLINDER GP90
Do not forget to place the washers! (see diagram 5.5)
5.5 MOUNTING THE CYLINDER HEAD
1. Mount the cylinder head and tighten the eight M6 screws with 12Nm
of torque and the four M5 screws with 6Nm of torque.
Diagram 5.5
1.11
1.11
1.8
1.12
1.9
1.10
1.9
1.10
1.8
1.12
1.8
1.12
1.9
1.10
1.9
1.10
1.8
1.12
1.11
1.11
1.8
1.7
1.7
1.8
Parts used:
1.8
8x
Washer Ø 6 mm
1.9
4x
Washer Ø 5 mm
1.10
4x
1.11
6 Nm 4 x
Screws M5 x 25 mm
1.12
12 Nm 4 x
Screws M6 x 20 mm
1.7
12 Nm 2 x
Screws M6 x 25 mm
10 Nm
Vent connections
6. WATER COOLING
9. RUNNING-IN THE ENGINE
To ensure a constant operating temperature of 50°, the original radiator
should be replaced by a larger model (or two serial models). The minimum operating temperature is 45°. The maximum operating temperature of 60 ° must not be exceeded.
10. MAINTENANCE ADVICE
1. Attach all coolant tubes to the cylinder.
2. Connect the two venting ports of the cylinder head with the original
4 mm tubes.
3. Fill the cooling circuit with coolant.
4. Disconnect the tubes from the two venting ports until no more air
emerges. Reconnect the tubes to the ports after venting.
7. IGNITION
We strongly recommend the use of a digital inner rotor ignition. To fully
exploit the potential of the MXS GP90 cylinder, chose an ignition timing
Stage6 R/T PVL ignition between 4.2 mm and 4.7 mm before TDC for
gearshifter and 4 mm and 4.5 mm before TDC for scooters.
Min Horiz. LC: S6-4516600
AM6: S6-4518800
Derbi E2 / E3: S6-4519200
8. FUEL
To avoid the risk of detonation use fuel of at least 100 octane (RON).
Do not use any E10/E85 fuel since it is not compatible with commercial
2stroke oils. Make sure to use high quality oil. We recommend Castrol
A747 or Motul 800GP. Remove the original oil pump and use a 2% fuel/
oil-premix.
Before the first start of the engine, make sure the carburation is set on
too „rich“. Once this is ensured you can start the engine. Check if the
cooling system has been vented properly. Let the engine run at idle
speed for about 20-30 minutes until it reaches an operating temperature
of 65-70°. Then turn off the engine and allow it to cool for approximately
10 minutes. Repeat this procedure 2 more times and you can consider
the engine to be run-in. Now you can start with adjustment (carburetor,
ignition, transmission ...).
To guarantee a consistent performance and durability, you should test
the compression of the engine after it has been run in, remember this
value and verify it every 1.5-2 operating hours. If the compression is too
low, the piston ring or the piston itself has to be replaced. To avoid engine damage, you should also adjust the mixture preparation regularly/ at
a change of weather.
11. TUNING
If you require more power, we recommend the use of the combustion
chamber «Competition », which is available for all versions of the MXS
GP90. If that is still not enough, please contact the Maxiscoot competition-center at mxscustom@maxiscoot.com.
MOUNTING GUIDE : CYLINDER GP90
PORTMAP / SPARE PARTS
Ignition Timing MXS 90GP Version « Base »
Exhaust : 192° Transfer ports A: 130°, B:128°, C:124°
2.20
Combustion chamber(Comp.) 2.60
ABC
Combustion chamber (Base)
38.81
26.60
26.30
38
38.40
73.85 (Derbi Euro 2-3)
Diagram 6 a
74.50 (AM6)
Euro 2 + 3, AM6
Ignition Timing MXS 90GP Version « Competition »
Exhaust : 194° Transfer ports A: 132°, B: 130°, C: 126°
Ignition Timing MXS 90GP Version « Base »
Exhaust : 194° Transfer ports A: 130°, B: 127°, C: 124°
All parts of the MXS Racing GP90 serie are
available in our onlineshop :
www.maxiscoot.com
Combustion chamber(Comp.) 3.40
ABC
Combustion chamber (Base) 3.10
38.81
26.60
26.30
38
38.40
Diagram 6 b
74.80
07
Min horiz. LC
Ignition Timing MXS 90GP Version « Competition »
Exhaust : 196° Transfer ports A: 132°, B: 129°, C: 126°
SPARE PARTS
Cylinder head cover
MXS120906-04 Cylinder head cover MXS GP90 AM6 / Derbi Euro3
MXS120906-03 Cylinder head cover MXS GP90 Derbi Euro2
MXS120906-02 Cylinder head cover MXS GP90 Min. horiz. LC
Combustion chamber
MXS46GPBASE
MXS45GPBASE
MXSGP46COMP
MXSGP45COMP
Combustion chamber MXS GP90 Base AM6 / Derbi
Combustion chamber MXS GP90 Base Min. horiz. LC
Combustion chamber MXS GP90 Comp. AM6 / Derbi
Combustion chamber MXS GP90 Comp. Min. horiz. LC
Sealing plug set
MXS120906-1 Kit sealing plugs alu MXS GP90 AM6 / Derbi Euro3
MXS120906-2 Kit sealing plugs alu MXS GP90 Derbi Euro2
MXS120906-3 Kit sealing plugs alu MXS GP90 Min. horiz. LC
MXS GP90 SERIE:
Cylinder kit
MXSGP006
MXSGP002
MXSGP003
MXSGP008
Crankshaft
MXS64690
MXS24690
MXS34690
MXS84590
Exhaust
MXS385
MXS365
Cylinder MXS GP90 travel 46mm AM6
Cylinder MXS GP90 travel 46mm Derbi Euro2
Cylinder MXS GP90 travel 46mm Derbi Euro3
Cylinder MXS GP90 travel 45mm Min. horiz. LC
Centering pins sealing plugs
MXSNRA2X63G2 centering pins sealing plugs, universel
Piston complete
Crankshaft MXS GP90 AM6
Crankshaft MXS GP90 Derbi Euro2
Crankshaft MXS GP90 Derbi Euro3
Crankshaft MXS GP90 Min. horiz. LC
MXS06139050A Piston complete MXS GP90 cote A
MXS06139050B Piston complete MXS GP90 cote B
MXS06139050C Piston complete MXS GP90 cote C
Piston ring
Exhaust MXS GP90 AM6 / Derbi
Exhaust MXS GP90 Min. horiz. LC
MXS11139050 Piston ring MXS GP90 universel
Casket & o-ring set
Pack cylinder crankshaft
MXSGP006P1
MXSGP002P1
MXSGP003P1
MXSGP008P1
Pack cylinder crankshaft
Pack cylinder crankshaft
Pack cylinder crankshaft
Pack cylinder crankshaft
MXS GP90 course 46mm AM6
MXS GP90 course 46mm Derbi Euro2
MXS GP90 course 46mm Derbi Euro3
MXS GP90 course 45mm Min. horiz. LC
Pack cylinder crankshaft exhaust
MXSGP006P2
MXSGP002P2
MXSGP003P2
MXSGP008P2
Pack cylinder crankshaft exhaust MXS GP90 course 46mm AM6
Pack cylinder crankshaft exhaust MXS GP90 course 46mm Derbi Euro2
Pack cylinder crankshaft exhaust MXS GP90 course 46mm Derbi Euro3
Pack cylinder crankshaft exhaust MXS GP90 course 45mm Min. horiz. LC
MXS14139050
MXS14089750
MXS14089850
MXS14074050
Casket & o-ring set MXS GP90 AM6
Casket & o-ring set MXS GP90 Derbi Euro2
Casket & o-ring set MXS GP90 Derbi Euro3
Casket & o-ring set MXS GP90 Min. horiz. LC
Washer set
MXS15139050 Washer set MXS GP90 universel
Screws M7
MXSGPM735
MXSGPM730
MXSGPM725
2 x Screws M7 35mm
2 x Screws M7 30mm
2 x Screws M7 25mm