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Malossi MHR innerrotortändsystem. En racingtändning från Malossi med innerrotor och dynamisk tändtidpunkt.
MHR Team ignition is a great innovation!!!Manages multiple maps simultaneously without having to resort to a hand-held device, with just
a simple click.
Ability to shift the selected map by moving the OFFSET (± 2°).
The inner rotor ignition systems designed by Malossi are based on the state-of-the-art technology
applied to racing.
Such a new system resulted from the need to overcome the technical limitations imposed by
conventional fl ywheel ignition, which cannot ensure consistent performance over 10,000 rpm
and causes severe setting-up problems for racing vehicles.
We dramatically
modifi ed the control unit to create two new Inner Rotor Ignitions: MHR and
MHR Team.
We made the control unit even more immune to interferences developing an uP STM8 - 8 bit
microprocessor with processing speed of 20MIPS, guaranteeing spark timing with greater
accuracy than prior versions!
The MHR version includes a control unit with variable spark advance timing, not adjustable.
The MHR Team includes a control unit with variable spark advance timing and with 3 trimmers:
- the fi rst trimmer (MAPS) is for selecting the spark advance timing map
- the second trimmer (OFFSET) allows you to shift the selected map ± 2°
- the third trimmer (LIM) used especially for 4-stroke engines, permits you to vary the rev limit between
11.500 RPM to 14.300 RPM and also allows you to disable the rev limiter
It also features 8 preset maps described as follows:
- 2 variable spark advance maps for 4 stroke engines
- 5 variable spark advance maps for 2 stroke engines
- 1 fi xed spark advance map
This ignition kit does not need any further part to work.
It does not affect the original electric system (it produces no voltage to feed lights and
services).
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TECHNICAL FEATURESCDI MHR TeamControl unit with variable spark advance timing and with 3 trimmers:
- trimmer MAPS: selects the spark advance timing map
- trimmer OFFSET: shifts the selected map ± 2°
- trimmer LIM: selects the rev limit (16 possible settings)
- 8 preset maps:
- 2 variable spark advance maps for 4 stroke engines
- 5 variable spark advance maps for 2 stroke engines
- 1 fi xed spark advance map
- System based on a uP STM8 - 8 bit microprocessor with a processing speed of 20MIPS
(Million Instructions Per Second).
- Reduced processing time, improved spark advance precision and stability.
- Hardware architecture with improved immunity to interferences.
- Temperature class 105°C cable.
- Compensation for flywheel fitting error of ± 2°
with 0.5° increments via an external trimmer
- 8 spark advance tables selectable via an
external trimmer
- Vector spark advance tables comprised of 24
breakpoints with linear interpolation.
- Adjustable rev limit via an external trimmer
with 16 settings.
- Soft cut feature insures a gradual rev limit cutoff.
- 15 settings to adjust the rev limit between
11,500 RPM and 14,300 RPM with 200 RPM
increments plus a setting to disable the rev
limiter.
ATTENTION : The control unit has an adjustable RPM
limit function to prevent engine damage. Rotating the
trimmer with a screwdriver will adjust the rpm limit
between a range of 11,500 to 14,300, or exclude the limit
function altogether. Every click corresponds to 200 RPMs.
CDI MHR- Variable spark advance
- System based on an uP STM8 - 8 bit microprocessor with a processing speed of 20MIPS
(Million Instructions Per Second).
- Reduced processing time, improved spark advance precision and stability.
- Hardware architecture with improved immunity to interferences.
- Temperature class 105°C cable.
- Vector spark advance tables comprised of 24 breakpoints with linear interpolation.
High voltage coil
- Capacitive discharge
- Ultra high effi ciency
- Constant 30,000 V discharge voltage up to 20,000 rpm
Rotor-stator unit
- Small (Ø 58 mm) and light inner rotor
- Permanent magnet rotor ensuring excellent performance
- Unprecedented effi ciency with minimum weight
WARNING :
with this kind of ignition the lighting set is disconnected.
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Monteringsanvisningar 1 - Förarbete- Tvätta hela scootern, speciellt motorn där arbetet skall utföras.
- Koppla ur och ta bort batteriet.
2 - Demontering - Minarelli motorer1. Ta bort kylvätskepumpen
2. Lossa de tre muttrarna som driver kylpumpen och ta bort dem från svänghjulet.
3. Skruva loss muttern som låser svänghjulet på vevaxeln, ta loss svänghjulet med hjälp av svänghjulsavdragaren.
4. Ta bort spolarna ,pickupen och kablarna
3 - Montering - Minarelli / Yamaha-motorer1. Montera Malossi bottenplatta på motorblocket (dra åt bultarna gradvis i ett kryss mönster)
2. Passa sedan in krysskilen på vevaxeln
3. Montera sedan rotorn dra åt låsmuttern till 30 Nm.
4. Montera statorn på flänshållaren och montera kablar utan att skada dem.
5. Dra åt statorn lite grand med hjälp av de 3st M5 skruvarna (skall justeras och dras åt senare)
6. Kontrollera att rotorn roterar utan problem, annars eliminera orsakerna.
Minnestips
Statorn = Statisk (står still)
Rotorn = Roterar (rör sig)
Dessa minnestips hjälper dig att komma ihåg vad som är vad
Det är samma sak som på elmotorer4 - Inställning tändning1. Montera indikatorklockan i tändstiftshålet
2. Vrid motorn moturs till övre dödpunkt uppnåtts
(När indikatorklockans visare vänder har motorn nått övre dödpunkten)
3. Montera gradskivan och visaren
- Visaren skall peka på noll grader på gradskivan
4. Fortsätt att rotera motorns moturs tills visaren pekar på 32-33 grader
(Det är värdet jag läst av i tabell 1 (tillverkarens rekommendation)
5. Lossa gradskivan utan att rubba vevaxeln
6. Justera referensmarkeringen på rotorn med statorns referensmarkering
(Gör detta genom att vrida på statorn)
7. Dra fast de tre skruvarna på statorn
- Montera brickan för vattenpumpsdrivningen
- Drar sedan fast muttern på vevaxeln med rätt moment
(lås variatorn med variatorspärren)
- Montera bultarna som driver vattenpumen
5 - Inkoppling kablage- Sätt i den nya Malossi högspänningspolen anslut jorden och tändkabeln.
- Den svarta kabeln med ringkabelskon och det lilla flatstiftet måste vara ansluten till lilla spolens anslutning.
- Jordpunkten måste vara densamma som för spolarna.
- Det rekommenderas att en enda jordningspunkt för hela tändsystemet används, där spolen jordkabeln (svart), styrenhetens jordledningen (svart med ringkabelskon) och jordkabeln av den högspänningspolen (se diagram sid 19) ansluts.
- Montera den nya Malossi CDI´n (elektronikboxen) på fordonet.
- Anslut statorns kablarna till CDI´n via kabelskon.
- Anslut den orange kabeln med det stora flatstiftet till den stora anslutningen på högspänningspolen.
- Anslut den svarta kabeln kontrollenheten till den gemensamma jordpunkten på det nya systemet (se diagrammet sid. 19).
- Röd tråd är för motorns "dödarknapp" (dödarknapp skall ansluta mot jord).
6 - Kontroll av tändning med hjälp av stroboskoppistolOm du har en bra stroboskoppistol med en display för att läsa grader förtändningen kan du
göra en dynamisk kontroll på följande sätt.
1. Kör motorn till sin övre dödpunkt och genom att använda en tunn spets
penna eller en drawpoint, märke på rotorn ett referensmärke där det matchar markeringen på statorn.
2. Ta bort mätklocka, montera tändstiftet ansluter den till högspännings-kabel, anslut
stroboskop pistol och starta motorn stabilisera den vid 4.000 rpm.
3. Genom att använda vapnet kollimator
rikta referensmärket på statorn med markeringen dras på rotorn. Om alla verksamheter var
genomförs tillfredsställande, bör vapnet displayen visar den avancerade vinkeln som anges i tabell 1
(± 2 ° grader).
För att få en god tandning, med omsorg kontrollera att avståndet mellan elektroder av
tändstiftet är 0,45 mm.
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ASSEMBLY INSTRUCTIONS- Thoroughly wash the whole vehicle, especially the engine area where work will be
performed.
- Disconnect and remove the battery.
- Air-cooled engines: remove the air pipe and the cooling fan fi tted on the ignition fl ywheel.
- Minarelli engines: remove the aluminium cover supporting the cooling fl uid pump. Loosen
the three nuts driving the cooling fl uid pump and remove them from the ignition fl ywheel.
- After unscrewing the nut locking the ignition fl ywheel on the crankshaft, remove the ignition
fl ywheel by using special extractors. Remove the stator-holding fl ange / the pick-up.
- Remove the high voltage coil and the original control unit from the vehicle.
- Disconnect and eliminate all cables supplying power to the other electrical devices (such as
lights, charger, battery, etc.).
- Remove the original stator.
Minarelli/Yamaha engines:
Fit the Malossi base plate on the engine casing by gradually
tightening the 3 screws provided, carefully fit the key in its seat of the crankshaft and then fit
the rotor perfectly timed with the key and tighten the rotor-locking nut by applying a 30 Nm (3
kgm) torque.
Assemble the stator on the holding flange correctly and fit the cable without damaging it.
Secure the stator by means of the 3 M5 screws supplied without locking it in order to allow a
correct timing by manual rotation of the stator. Make sure that the rotor turns without problems,
otherwise eliminate the causes.
IGNITION TIMINGTurn the engine anti-clockwise to the top dead centre and zero the dial indicator checking the
exactitude of the operation. Go on with the anti-clockwise engine rotation until the dial indicator
marks the distance indicated in
Table 1 (static keying advance) from the top dead centre. Keeping the
crankshaft in this position, align the reference mark on the rotor with the mark drawn on the stator by
turning the stator, then tighten the three stator fastening screws.
ELECTRICAL CONNECTIONS- Insert the new Malossi high voltage coil and carefully ground it. Connect the spark wire.
- The black cable with the eyebolt terminal and the small faston must be connected to the
small coil terminal. The eyebolt must be connected to the coil ground.
It is recommended that a single grounding point for the whole ignition system should be used,
where the coil earth wire (black), the control unit earth wire (black with eyebolt terminal) and
the earth wire of the high voltage coil (see diagram pg. 19) should be connected.
- Assemble the new Malossi electronic control unit on the vehicle.
- Connect the stator cables to the control unit by means of the cable terminal plug.
- Connect the orange cable provided with the big faston to the big terminal on the high voltage
coil.
- Connect the black control unit cable to the common ground terminal of the new system (see
diagram pg. 19).
- Red wire for engine kill switch.
- Connect the red wire to the switch (NOT included in the kit), ground the switch.
This is not a necessary connection for the correct operation of an ignition with an internal rotor.
TIMING CHECK WITH STOBOSCOPE GUNIf you have a good stroboscope gun with a display to read the spark advance degrees, you can
make a dynamic check as follows. Drive the motor to its top dead centre and, by using a thin tip
pen or a drawpoint, mark on the rotor a reference mark where it matches the mark on the stator.
Remove the dial indicator, fi t the spark plug connecting it to the high-voltage cable, connect the
stroboscope gun and start the engine stabilizing it at 4,000 rpm. By using the gun collimator
align the reference mark on the stator with the mark drawn on the rotor. If all the operations were
properly performed, the gun display should show the advanced angle as indicated in
Table 1(± 2° degrees).
In order to have a good ignition, having care to check that the distance between electrodes of
the spark plug is 0.45 mm.
Minarelli/Yamaha water-cooled engines - pump on the casing ( 5514690 ): assemble the Malossi
driving flange onto the rotor and fi t the three screws driving the cooling fl uid pump into the flange.
We hope you found the above instructions suffi ciently clear. However, if any points are not
particularly clear, please contact us completing the special form inserted in the “contact”
section on our Internet site (
http://www.malossi.com). We thank you in advance for any comments
and suggestions you may wish to send us. So goodbye from us all at Malossi, and please accept
our compliments. Have Fun. GOOD LUCK and … see you next time.
The descriptions in this publication are not binding. Malossi reserves the right to make
modifi cations, if it considers them necessary, and does not accept any responsibility for any
typographic or printing errors. This publication replaces all previous publications referring to the
updating matters contained therein.
WARRANTY: Look up warranty terms in our website
http://www.malossi.com.
These products are reserved solely for races in locations reserved for those purposes and
in accordance with the regulations issued by the competent authorities for sports events.
We decline any and all responsibility for improper use.