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View Full Version : Malossi upgear kit

scootinforlife247
11-16-2004, 10:39 AM
is there some one could write a how to on installing this item
Zuma88
11-16-2004, 10:40 AM
contact jered he just did this
XPS1210
11-16-2004, 12:11 PM
It's really not a how to as it's pretty simple...

1. drain oil via plug on bottom of case... open fill plug to assist with draining

2. remove tranny cover

3. after oil is drained remove the bolts that hold the gear cover in place (be very careful not to tear the gasket).

4. take gears out

5. have old gears pressed off and new gear pressed on

6. put gears back in

7. replace cover

8. fill with 10w30 .1 of a quart

9. check for leaks

10. install tranny cover back on.

your done... the hardest part is the gears need to be pressed on.. Trust me...
thanasi
01-21-2006, 07:52 PM
could you elaborate on what "pressing the gears" actually is?
speedy_scooter
01-21-2006, 08:09 PM
Its taking out the stock gears, using a hydraulic press to "press" them out. And then you put in the new ones in the same way. Pressing is just how you take them out with alot of pressure or force.
XPS1210
01-21-2006, 10:58 PM
you can do it with a hammer and such... but be careful not to damage the ends of the gears and shafts... they get mushroomed and you have problems...

the pressing is using a hydrolic press or hand operated press... there are some cheap home ones that are under $100... but still will do the job easily...

or take it to a automotive shop and they can usually do it and probably for a couple bucks... I got charged $7.00 for mine I think...
Red Herring
01-22-2006, 08:30 AM
If you use a hammer, use a brass one, or at least a brass drift. Otherwise, you will likely damage the gears.
florida derbi rocket
01-22-2006, 05:37 PM
Has anyone done the Gears the freeze/bake way?..like how you do a crank?...I swear...those frozen bearings just Dropped right in..interference fit was canceled. My Derbi service manual has you use a Heat gun to take the gears out, 80 degrees celcius, (176 F).
str8dum
01-22-2006, 06:58 PM
none of that works. I';ve tried. When you turn that 10 ton press you'll know that heat wont get those off.
xraydino
02-01-2006, 08:51 PM
When you do the up gear install do you have to change anything else to compensate? What I mean is after endless tuning and trial and error to find the best ballance do you have to start over again with torque spring, weights and such?
str8dum
02-02-2006, 02:14 PM
yeah you have to start over again with the rollers at least. CLutch engagement and torque spring might also need to be changed. All depends on how you had it set before gears. Prolly need lighter weigths to keep the vario closed longer.

Its been so long since i've not had gears I cant remember what all i needed to do. Rollers,torque spring, abnd clutch engagement i think.