Malossi Variator Kit for Vespa Sprint/Primavera

Step-by-Step Tutorial: Installing Malossi Variator Kit for Vespa Sprint/Primavera

1. Introduction to the Malossi Variator Kit:

   • The Malossi Variator Kit is compatible with various Vespa models, including the new Primavera and Sprint 946, as well as the newer style Fly 150.
   • The kit includes a different Contra spring and 13.5 gram roller weights for improved performance and throttle response.

2. Preparation:

   • Gather the necessary tools including a variator holder (such as the tool ETV1), a 19mm wrench, a 34mm socket, and a torque wrench.
   • Ensure the scooter is securely placed and stable for the installation process.

3. Accessing the Variator:

   • Remove the airbox by unscrewing and lifting it up to access the variator area.
   • Remove the belt cover by unscrewing the 8mm clamps and carefully prying it off to reveal the variator components.

4. Disassembling the Clutch:

   • Remove the center nut on the clutch using a 19mm wrench.
   • Carefully disassemble the clutch components, including the clutch drum and fixed half of the variator.

5. Replacing Components:

   • Install the Malossi variator components including the roller weights, ramp plate, and guides as per the kit instructions.
   • Ensure proper alignment and orientation of the components before assembly.

6. Reassembling the Clutch:

   • Reassemble the clutch components ensuring proper alignment and torque specifications.
   • Use Loctite on critical fasteners and verify torque settings for secure assembly.

7. Installing the Belt:

   • Install the belt in the correct direction and position it properly in the driven pulley.
   • Use both hands to open up the driven pulley and carefully drop the belt into place to prevent pinching.

8. Final Assembly:

   • Reassemble the remaining components including the clutch bell, shim washers, and belt cover.
   • Secure all fasteners to the specified torque settings to ensure proper installation.

9. Verification and Testing:

   • Verify that all components are securely installed and aligned correctly.
   • Start the scooter and test the performance to ensure the Malossi Variator Kit is functioning as intended.

10. Fine-Tuning (Optional):

    • If desired, experiment with different roller weights for fine-tuning the scooter's performance.
    • Make incremental adjustments to the weights to achieve the desired gear ratios and throttle response.

11. Completion:

    • Once satisfied with the installation and performance, ensure all components are properly secured and the scooter is ready for use.
    • Regularly inspect and maintain the Malossi Variator Kit to ensure optimal performance and longevity.

By following these step-by-step instructions, you can successfully install the Malossi Variator Kit for Vespa Sprint/Primavera and enhance the performance of your scooter.