MOUNTING GUIDE

ENG
XX-MXS-EBAMXS900-1
08/2015

TWIN CYLINDER
CRANKCASE
FOR:
AEROX / NITRO
SKU.: MXS900

Consultez la dernière version de la notice de mon-

tage en PDF sur www.mxsracing.com

The latest version of this mounting guide in English

is available as a PDF download at
www.mxsracing.com
01 MOUNTING GUIDE : TWIN CYLINDER CRANKCASE

CONTENTS Page 2. CONTENTS BASIC KIT

1. Introduction 1 - Twin Cylinder Crankcase CNC MXS Racing 49mm stroke / 95mm conrod
1.1 Requirements 1 Sku: MXS900
- Twin Cylinder Crankshaft MXS Racing 49mm stroke / 95mm conrod
2. Contents Basic Kit 1
Sku: MXS84995/TWIN
3. Recommended Engine Configuration 1 - 4 x Crankshaft Bearings
4. Milling Guide OEM Crankcase YAMAHA/MBK Sku: SKF6005-2RSLTN9/C3VT162 (inside)
4.1 Cylinder Base 2 Sku: SKF6005TN9/C3 (outside)
4.2 Passage for Connecting Rod 2 - 6 x Stud Bolts 180mm
4.3 Crankcase 2 Sku: EKP-WG99
4.4 Crankshaft 2 - 2 x Oil Seals for Crankshaft Viton / Teflon
4.5 Bearings 25mm 2 Sku: P285.0002
4.6 Surface Grinding 3 - 2 x Intake Spacers Twin Cylinder MXS Racing
4.7 Kickstarter 3 Sku: MXS900010
4.8 Oversize Variator 3 - 2 x Intake Manifolds d = 40mm for Spacers Twin Cylinder MXS
5. Assembly Sku: MXS900011
5.1 Mounting Crankcase 4 - 2 x Intake Adapters d = 40mm
5.2 Mounting Cylinders 4 Sku: MXS900012
5.3 Ignition Timing 4 - Installation Guide
5.4 Mounting Intake 4
5.5 Mounting Variator 4
5.6 Mounting Case to Chassis 4 3. RECOMMENDED ENGINE CONFIGURATION
6. Running In 4 - Crankcase Minarelli w/ rear disc brake Yamaha Aerox / MBK Nitro
Sku: OE-ITJ440703209
7. Cooling System 4
- Cylinders MXS GP 2 90cc 45mm stroke Yamaha Aerox / MBK Nitro
8. Fuel 4 Sku: MXSGP008
9. Maintenance 4 - Reed Valves Bidalot „V-Force 3i“ Honda CR85
Sku: BID13700870
- Carburetors Keihin PWK 35mm (main 170 – pilot 50)
Sku: KH-900102
- Variator Stage6 R/T Oversize Yamaha Aerox / BW‘s (weights 10 - 12g)
Sku: S6-5616634
PLEASE READ THIS MANUAL - Drive Belt Stage6 R/T for Oversize Variator Yamaha Aerox / BW‘s
THOROUGHLY TO AVOID Sku: S6-5916627
SEVERE ENGINE DAMAGE ! - Clutch d = 112mm Stage6 Racing Torque Control MK II
Sku: S6-5016614 (use all weights + put springs at half tension)
- Clutch Bell Stage6 Racing Wing Cooler d = 112mm
GUARANTEE – EXCLUSIONS Sku: S6-5516609
The MXS Racing CNC Twin Cylinder Crankcase has a guarantee - Transmission Cover Polini Yamaha Aerox / BW‘s
against all manufacturing defects that are detected before installati- Sku: U170.0301
on. Defects and signs of wear caused by normal use or by external - Primary Transmission 14/42 Malossi
effects (faulty assembly or disassembly, incorrect maintenance, Sku: M6714733
inappropriate use, etc.) or by modifying the product in ways not
- Secondary Transmission 15/42 Polini
intended or specified by the vendor are exempt from guarantee. For
Sku: P202.1346
more information, please contact vendor.
- Variator Cover Polini Yamaha Aerox / MBK Nitro
Sku: P170.0305 / P170.0303
1. INTRODUCTION - Swingarm Polini „Torsen WD“ Yamaha Aerox / MBK Nitro
We thank you for your trust and confidence by purchasing the MXS
Sku: P172.0016
Racing CNC Twin Cylinder Crankcase. This installation guide will
provide you with all the necessary information for making optimum
use of your new engine set-up and for obtaining maximum perfor-
All the MXS Racing GP90 Parts are available
mance.
in our Onlineshop: www.maxiscoot.com

1.1 REQUIREMENTS
If you do not have the technical know-how, experience and tools to
perform the installation, we recommend contacting a 2-stroke engine
expert as to be able to exploit the full potential of your new set-up.
02 MOUNTING GUIDE : TWIN CYLINDER CRANKCASE

4. MILLING GUIDE OEM CRANKCASE Illu. 4.3

4.1 CYLINDER BASE
Crankcase and variator cover should be in very good condition,
without any signs of corrosion. It is important to use ALL variator
cover bolts to ensure the level of rigidity and stability necessary for
this set-up.

4.2 PASSAGE FOR CONNECTING ROD

The original crankcase cylinder base seat has to be bored before
use. (ill. 4.2.a)
- Bore: 58.2mm
- Depth: 10mm
Clearance cuts for the passage of the connecting rod have to be
milled as well. (ill. 4.2.b) Surface Grinding 2,5mm (± 0,05mm)

Milling Original Cylinder Base Seat

4.3 CRANKCASE
The MXS CNC twin cylinder crankcase is wider than the original
Illu. 4.4
one by 5mm. This requires milling down the sides of the original
crankcase (ignition and variator side) by 2.5mm (± 0.05mm).
Perfectly level seating of the crankcase is really important. This
5mm difference is necessary for mounting the 49mm stroke MXS
crankshaft with oversized crankwebs. (ill. 4.3)

4.4 CRANKSHAFT
Milling for crankshaft webs MXS 49mm stroke.
Bore: 82.5mm (ill. 4.4)

4.5 BEARINGS 25MM

Milling for 25mm bearings. The bearings are a little „slimmer“ to
compensate for the larger webs; the original crankcase has to be Diameter 82,5mm (± 0,2mm)
milled down by 1.5mm (± 0.1mm). (ill. 4.5)
Milling for Crankshaft

Illu. 4.2a Illu. 4.5

Ø 58,2 mm
Depth 10 mm (± 0,1mm)
Depth 1,5 mm (± 0,1mm)
Milling Cylinder Base Milling for Bearings 25mm

Illu. 4.2b

Milling Passage for Connecting Rod

03 MOUNTING GUIDE : TWIN CYLINDER CRANKCASE

Illu. 4.6

Make sure that the cylinder contact area is level

4.6 SURFACE GRINDING Illu. 4.7a

Make sure that the cylinder contact area, between the new MXS
Racing CNC crankcase and the original Minarelli crankcase,
is perfectly level. It is very important that the cylinder bases are
placed at the exact same height.
(ill. 4.6)

4.7 KICKSTARTER
In order to obtain maximum stability, the variator-side crankshaft
spline is longer and provides the option of adding a bearing inside
the variator case. This way torsion rigidity during acceleration is
increased. There are two options:

- Cut the end of the spline down to where the threaded part
Keep kickstarter
begins; in this case you can keep the kickstarter, and the extra
support by the bearing cannot be used. (ill. 4.7.a)
Illu. 4.7b
- Heat the variator cover to remove the kickstart pinion gear shaft.
Place the additional bearing (sku MXS….). In this case you‘ll have
to use an external starter motor. (ill. 4.7.b)

4.8 OVERSIZE VARIATOR

If using an oversize variator, refer to instructions given by variator
manufacturer.

Use external starter and increase torsion rigidity

04 MOUNTING GUIDE : TWIN CYLINDER CRANKCASE

5. Assembly 6. RUNNING IN
5.1 MOUNTING CRANKCASE Before starting the engine make sure that the carburetor main jet
The actual centrepiece of the MXS Racing crankcase comes is „too big“ so the mixture will be too rich. After start-up, synchro-
pre-assembled, and once all the milling is done, the variator case nize the carburetors and let the engine idle for approx. 20 minutes.
and ignition can be assembled and mounted. Two SKF bearings Keep an eye on the temperature while doing so. Then let the
(25x47x12mm) are included in the kit, we recommend placing engine cool down again for 10 minutes. Restart the engine. You
them on the splines in advance. should do this two times minimum. Then open the throttle and
To do this, heat the variator-side journal with a heat gun. When it readjust carburetors again.
is warm enough, insert it into the crankcase; the crankcase has to Attention: as a twin cylinder set-up has plenty of torque, you
be mounted with sealing compound to its prepared contact area in should go easy on the clutch in the beginning.
advance. Please note that the entire assembly is quite heavy, we
recommend blocking the rear part of the variator cover to avoid
tipping. 7. COOLING SYSTEM
Now do the same on the ignition side of the crankshaft. 7.1 B uy two Y-connectors for the cooling system of this twin
Now that the actual assembling is finished, place the 6 stud bolts cylinder engine available in any hardware store.
and fasten them with the 6 nuts. 7.2 Connect the lower outlet of the radiator to the water pump,
then connect the Y-piece. Now both cylinders can be sup-
plied with water through the ports at the cylinder base.
5.2 MOUNTING CYLINDERS
7.3 Connect the two hoses coming out of the cylinder head to the
We strongly recommend using two MXS Racing GP2 cylinders for
other Y-connector to return the coolant to the upper inlet of the
this twin cylinder set-up. Before installing them, you should mark
radiator.
them as left and right cylinder. Mount the two cylinders using the
7.4 Use the original hose (d = 4mm) to link the 2 drain screws
thickest base gasket; check squish clearance with a 0.7mm solder
on the cylinder head and fasten it with a hose clamp on each
wire. Measure squish by turning the motor with the kickstarter
side. Do the same with the second cylinder.
or the electric starter. Note that the cylinders do not necessarily
7.5 Refill cooling system with coolant.
have the same squish clearance. For optimum performance, you
7.6 Detach the hose form one of the drain plugs to bleed out
should settle on a 0.55mm squish for both cylinders. Once the
excess air. Reconnect the hose as soon as the liquid does
squish clearance is properly adjusted, mount the cylinders follow-
not contain bubbles any longer. Do the same with the second
ing the instructions given by the manufacturer.
cylinder.
5.3 IGNITION TIMING
The original radiator has to be replaced with a larger, more ef-
This twin cylinder set-up is a straight-twin engine with 180° crank-
ficient model capable of keeping an ideal temperature of 50°C
shaft angle with two power strokes in each revolution. Ignition
(maximum 60°C). It is also possible to join up two radiators to get
timing has to be readjusted accordingly. Please check the instruc-
the same results.
tions given by the manufacturer.

5.4 MOUNTING INTAKE 8. FUEL

Two intake manifolds and two spacers are included in delivery. We strongly recommend using fuel with an octane rating of 98
Mount them on the twin cylinder case; use appropriate reed (minimum). Do not use E10/E85 fuel. We also recommend using
valves (Derbi or CR 85). And don‘t forget to seal the entire intake very high quality oil such as Castrol A747 or Motul 800GP. Fuel-oil
properly. mixing ratio is 2%.
Now mount the two carburetors. We recommend adjusting them
so their settings are identical (needle height – main jet – pilot jet – 9. MAINTENANCE - TIPS FOR OPTIMIZATION
power jet – mixture screw – idle screw – float bowl level) so it will An engine can only be powerful and reliable when properly taken
be easier to readjust them after the first run. care of. This is why we recommend to check the condition of pis-
ton / piston ring every two hours of operation (approx.). Once the
5.5 MOUNTING VARIATOR engine is run in it is recommended to measure the cylinder com-
We recommend getting a new variator for this set-up. pression with an appropriate gauge. Knowing the initial compres-
We strongly advise against using the original variator as it won‘t sion the cylinder starts out with helps in knowing when it becomes
be compatible with the obligatory reinforced primary and second- too low so the problem can be fixed. You can find all replacement
ary transmission (by Polini, Malossi or Top Performances). parts for the MXS GP90 cylinder kit in our webshop.

5.6 MOUNTING CRANKCASE TO CHASSIS

Now mount the entire assembly to the chassis; make sure that
everything is properly fastened.
Connect the crankshaft to the ignition.
Drain and refill the coolant system completely and make sure that
the battery is sufficiently charged to run the water pump (refer to
#7 below).
Connect switches.