MOUNTING GUIDE ENG XX-MXS-EBAMXSGP90 11/2014. MAXISCOOT - B.P F Forbach Cedex

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1 MOUNTING GUIDE ENG XX-MXS-EBAMXSGP90 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 F Forbach Cedex

The GP90 is the latest development of the MXS team, and the result of two years of intensive work.

2 01 E INTRODUCTION / MOTOR CONFIGURATION THE INSTALLATION INST- RUCTIONS 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. CHECK OUT ALL THE MXS GP 90 PRODUCTS ON THE LAST PAGE 1.1 PREREQUISITES To ensure the full potential and durability of the GP90 MXS cylinder, the following requirements have to be met: SYMBOL GEARED MOPED : Refers exclusively to Derbi Euro2 / 3 and AM6 engines SYMBOL SCOOTER : Refers exclusively to Minarelli horizontal engines 2. RECOMMENDED ENGINE CONFIGURATION 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. SPARK PLUG: NGK 105 IGNITION: Stage6 R / T (PVL) or Bidalot (PVL) GEARED MOPED: TRANSMISSION: Bidalot CLUTCH: Minimum 5-disc clutch SCOOTER : CVT GEARBOX: Overrange kit, Malossi, Stage6 or Polini RECOMMENDED TRANSMISSION: Primary 14/42, Secondary 16/41 (Street) Secondary 14/41 (Run) TABLE OF CONTENTS Page 1. Introduction Prerequisites 1 2. Recommended engine configuration 1 3. Scope of delivery 2 4. Milling the engine case 3 5. Installing the MXS GP90 cylinder kit 5.1 Mounting the cylinder Squish clearance Installing the sealing plug Installation of the cylinder head / combustion chamber Position of cylinder head bolts 6 6. Water cooling 6 7. Ignition 6 8. Fuel 6 9. Running in the engine Maintenance & Service Tuning Portmap Replacement parts 7

3 02 SCOPE OF DELIVERY 3. SCOPE OF DELIVERY Individual parts cylinder head: 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 Vent connections 8 x Washer Ø 6 mm EXPLODED VIEW CYLINDER HEAD Washer Ø 5mm Screws M5 x 25 mm Screws M6 x 20 mm Screws M6 x 25 mm Individual parts piston : EXPLODED VIEW PISTON Piston Piston ring Gudgeon pin Gudgeon pin clip Individual parts cylinder : Cylinder MXS GP 90cc Base gasket paper 0.2 mm 3 x Base gasket aluminum 0.1 mm Spacer cylinder base 5mm Exhaust flange gasket Water supply Washer Ø 24 mm Screws M7 x 35 mm Screws M7 x 30 mm 8 x Screws M7 x 25 mm O-rings sealing plugs Centering pin sealing plugs EXPLODED VIEW CYLINDER Sealing plug front left Sealing plug right front Sealing plug rear left Sealing plug back right

03 MILLING THE ENGINE CASE 4. MILLING THE ENGINE CASE 1.

1a + 4.1b) ø 77.3 mm + 0.2mm FOR GEAR SHIFT : 2. In Derbi engines the cylinder base seat of the engine case has to be extended by 2mm. (Diagram 4.2a + 4.2b) 3.

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.

4 03 MILLING THE ENGINE CASE 4. MILLING THE ENGINE CASE 1. To avoid irreparable damages caused by an extreme performance increase, engine block, gearbox and all bearings must be in perfect condition. Diagram 4.1a 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) ø 77.3 mm + 0.2mm FOR GEAR SHIFT : 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 + 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 5. After milling the entire engine case has to be cleaned meticulously! Ø mm Milling scheme engine case (cylinder) (only for Min. horiz. LC) Diagram 4.2a Diagram 4.2b Euro Euro mm View of millings engine case (only for Euro 2 + 3) Detailed view (only for Euro 2 + 3) Diagram 4.3a Diagram 4.3b Depth 3 mm Width 4 mm Milling scheme conrod recess (for, Min. horiz. LC) Detailed view (for, Min. horiz. LC)

5 04 CYLINDER ASSEMBLY 5. INSTALL ING THE CYLINDER 5.1 MOUNTING THE CYLINDER 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: Diagram 5.1a CUT 1. Lubricate the needle bearing and install the piston. 2. Lubricate the cylinder bore. 3. Use the 0.2mm paper gasket. FOR SCOOTERS : 4. Only 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) Diagram 5.1b CUT 30 Sectional drawing of the cylinder with indication of screw positions (only for ) Parts used : Min horz. LC Base gasket paper 0.2 mm 3.8 Base gasket aluminum 0.1 mm Spacer cylinder base 5mm Min horz. LC Nm 20 Nm 20 Nm Screws M7 x 35 mm Screws M7 x 30 mm Screws M7 x 25 mm 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 with the help of an online translation. Diagram 5.2 CUT 0.55 mm Sectional drawing squish clearance

6 05 CYLINDER ASSEMBLY Diagram 5.3b 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! MOUNTING THE SEALING PLUGS Once 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 Diagram 5.3a INSTALLING THE CYLINDER HEAD COVER AND COMBUSTION CHAMBER 1. Make sure the water deflector is mounted correctly (Diagram 5.4a) Diagram 5.4a 2. When inserting the combustion chamber, pay attention to the recess of its anti rotation lock. (Diagram 5.4b) Diagram 5.4b Position water deflector Position combustion chamber Parts used : 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 x O-rings sealing plugs Centering pin sealing plugs Sealing plug front left Sealing plug right front Sealing plug rear left Sealing plug back right

7 06 CYLINDER ASSEMBLY 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 Do not forget to place the washers! (see diagram 5.5) Parts used: x 6 Nm 12 Nm 12 Nm 10 Nm Washer Ø 6 mm Washer Ø 5 mm Screws M5 x 25 mm Screws M6 x 20 mm Screws M6 x 25 mm Vent connections 6. WATER COOLING 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. 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. 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: S AM6: S Derbi E2 / E3: S 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. 9. RUNNING-IN THE ENGINE 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 minutes until it reaches an operating temperature of 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...). 10. MAINTENANCE ADVICE 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 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.

07 PORTMAP / SPARE PARTS Diagram 6 a Ignition Timing MXS 90GP Version «Base» Exhaust : 192

60 Ignition Timing MXS 90GP Version «Competition» Exhaust : 194 Transfer ports A: 132, B: 130, C:

60 Combustion chamber(comp.) 3.40 Combustion chamber(comp.

Ignition Timing MXS 90GP Version «Competition» Exhaust : 196 Transfer ports A: 132, B: 129, C: 126

com MXS GP90 SERIE: Cylinder kit MXSGP006 Cylinder MXS GP90 travel 46mm AM6 MXSGP002 Cylinder MXS

Crankshaft MXS GP90 Derbi Euro3 MXS84590 Crankshaft MXS GP90 Min. horiz.

LC Pack cylinder crankshaft MXSGP006P1 Pack cylinder crankshaft MXS GP90 course 46mm AM6

crankshaft MXS GP90 course 46mm Derbi Euro3 MXSGP008P1 Pack cylinder crankshaft MXS GP90 course

LC Pack cylinder crankshaft exhaust MXSGP006P2 Pack cylinder crankshaft exhaust MXS GP90 course

Pack cylinder crankshaft exhaust MXS GP90 course 46mm Derbi Euro3 MXSGP008P2 Pack cylinder

cover MXS GP90 AM6 / Derbi Euro3 MXS120906-03 Cylinder head cover MXS GP90 Derbi Euro2

LC Combustion chamber MXS46GPBASE Combustion chamber MXS GP90 Base AM6 / Derbi MXS45GPBASE

AM6 / Derbi MXSGP45COMP Combustion chamber MXS GP90 Comp. Min. horiz.

sealing plugs alu MXS GP90 Derbi Euro2 MXS120906-3 Kit sealing plugs alu MXS GP90 Min. horiz.

8 07 PORTMAP / SPARE PARTS Diagram 6 a Ignition Timing MXS 90GP Version «Base» Exhaust : 192 Transfer ports A: 130, B:128, C:124 Diagram 6 b (AM6) (Derbi Euro 2-3) Ignition Timing MXS 90GP Version «Competition» Exhaust : 194 Transfer ports A: 132, B: 130, C: A B C A B C 3.10 Combustion chamber (Base) 2.20 Combustion chamber (Base) 2.60 Combustion chamber(comp.) 3.40 Combustion chamber(comp.) Ignition Timing MXS 90GP Version «Base» Exhaust : 194 Transfer ports A: 130, B: 127, C: 124 Ignition Timing MXS 90GP Version «Competition» Exhaust : 196 Transfer ports A: 132, B: 129, C: 126 All parts of the MXS Racing GP90 serie are available in our onlineshop : MXS GP90 SERIE: Cylinder kit MXSGP006 Cylinder MXS GP90 travel 46mm AM6 MXSGP002 Cylinder MXS GP90 travel 46mm Derbi Euro2 MXSGP003 Cylinder MXS GP90 travel 46mm Derbi Euro3 MXSGP008 Cylinder MXS GP90 travel 45mm Min. horiz. LC Crankshaft MXS64690 Crankshaft MXS GP90 AM6 MXS24690 Crankshaft MXS GP90 Derbi Euro2 MXS34690 Crankshaft MXS GP90 Derbi Euro3 MXS84590 Crankshaft MXS GP90 Min. horiz. LC Exhaust MXS385 MXS365 Exhaust MXS GP90 AM6 / Derbi Exhaust MXS GP90 Min. horiz. LC Pack cylinder crankshaft MXSGP006P1 Pack cylinder crankshaft MXS GP90 course 46mm AM6 MXSGP002P1 Pack cylinder crankshaft MXS GP90 course 46mm Derbi Euro2 MXSGP003P1 Pack cylinder crankshaft MXS GP90 course 46mm Derbi Euro3 MXSGP008P1 Pack cylinder crankshaft MXS GP90 course 45mm Min. horiz. LC Pack cylinder crankshaft exhaust MXSGP006P2 Pack cylinder crankshaft exhaust MXS GP90 course 46mm AM6 MXSGP002P2 Pack cylinder crankshaft exhaust MXS GP90 course 46mm Derbi Euro2 MXSGP003P2 Pack cylinder crankshaft exhaust MXS GP90 course 46mm Derbi Euro3 MXSGP008P2 Pack cylinder crankshaft exhaust MXS GP90 course 45mm Min. horiz. LC SPARE PARTS Cylinder head cover MXS Cylinder head cover MXS GP90 AM6 / Derbi Euro3 MXS Cylinder head cover MXS GP90 Derbi Euro2 MXS Cylinder head cover MXS GP90 Min. horiz. LC Combustion chamber MXS46GPBASE Combustion chamber MXS GP90 Base AM6 / Derbi MXS45GPBASE Combustion chamber MXS GP90 Base Min. horiz. LC MXSGP46COMP Combustion chamber MXS GP90 Comp. AM6 / Derbi MXSGP45COMP Combustion chamber MXS GP90 Comp. Min. horiz. LC Sealing plug set MXS Kit sealing plugs alu MXS GP90 AM6 / Derbi Euro3 MXS Kit sealing plugs alu MXS GP90 Derbi Euro2 MXS Kit sealing plugs alu MXS GP90 Min. horiz. LC Centering pins sealing plugs MXSNRA2X63G2 centering pins sealing plugs, universel Piston complete MXS A Piston complete MXS GP90 cote A MXS B Piston complete MXS GP90 cote B MXS C Piston complete MXS GP90 cote C Piston ring MXS Piston ring MXS GP90 universel Casket & o-ring set MXS Casket & o-ring set MXS GP90 AM6 MXS Casket & o-ring set MXS GP90 Derbi Euro2 MXS Casket & o-ring set MXS GP90 Derbi Euro3 MXS Casket & o-ring set MXS GP90 Min. horiz. LC Washer set MXS Washer set MXS GP90 universel Screws M7 MXSGPM735 Screws M7 35mm MXSGPM730 Screws M7 30mm MXSGPM725 Screws M7 25mm

USA SUPER SHIFTER 175cc

USA SUPER SHIFTER 175cc FEATURES Cylinder volume 174.46 cm³ (Max 176.6 cm³) Bore 63.90 mm Max. theoretical bore 64.26 mm Stroke 54.40 mm Distance between conrod centers 115 mm Cooling system Water Inlet