Super T-Max. MALOSSI S.p.A. - Via Roma, 118/I Calderara di Reno (Bologna) Italy - Tel Fax

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1 Super T-Max MALOSSI S.p.A. - Via Roma, 118/I Calderara di Reno (Bologna) Italy - Tel Fax

Malossi is proud to offer Super T-Max, a completely new gamma of products

MAXI WILD LION Homologated SUSPENSION BRACKET 25+ WHOOP DISC COUPLE MHR

titanium finish, elliptical cross section.

A chicane silencer system with the addition of sound absorbing mineral fi

Stainless steel exhaust tubes from the cylinder or to the silencer.

ber with rivets, creates a structurally stronger exhaust and eliminates

Shock absorber bracket kit for racing setting Greater overall stability

the rear end 25mm. The Newest Generation of Disk Brakes.

use in all weather conditions and types of terrain.

progressive and secure braking even under extreme conditions.

2 Malossi is proud to offer Super T-Max, a completely new gamma of products for the most popular Yamaha Maxi-Scooter and like always Made In Italy! MAXI WILD LION Homologated SUSPENSION BRACKET 25+ WHOOP DISC COUPLE MHR SCREEN Technical features Brushed stainless steel canister with anodized titanium finish, elliptical cross section. Stainless steel end caps with laser logo markings. A chicane silencer system with the addition of sound absorbing mineral fi bres, possessing high noise damping and nondegrading qualities. Stainless steel exhaust tubes from the cylinder or to the silencer. The final exhaust assembly procedure of joining metal bands and carbon fi ber with rivets, creates a structurally stronger exhaust and eliminates any exhaust gas leaks. Shock absorber bracket kit for racing setting Greater overall stability and handling and better ground clearance was attained thanks to raising the rear end 25mm. The Newest Generation of Disk Brakes. Light, non corrosive, non-warping, anti-stress: - studied for prolonged use in all weather conditions and types of terrain. The WHOOP DISC paired with Malossi MHR SYNT BRAKE PADS guarantee a progressive and secure braking even under extreme conditions. Aerodynamic, protective, perfectly interchangeable with the original, made with a superior acrylic PMMA material, smoke colour. Computer Aided Designed utilising precise dimensions to maximise rider visibility in a race tuck position, a serious race enhancement for your scooter.

RED CHILLI OIL FILTER W BOX FILTER RACING CLUTCH SPRING WHOOP DISC

media, unalterable in time, and insensitive to rapid temperature

greater quantity of harmful larger contaminants, in virtue of the

cotton gauze, oiled, and sandwiched between two epoxy-coated

Encased in a polyurethane frame, 30 ShA, insuring an excellent

original clutch, with high yield strength, galvanically treated

The different colouring indicates the load capacity of each spring

The spring kit permits up to a 500 rpm clutch engagement with 150

3 RED CHILLI OIL FILTER W BOX FILTER RACING CLUTCH SPRING WHOOP DISC Super T-Max Technical Characteristics Quality of the filtering media, unalterable in time, and insensitive to rapid temperature changes starting at 20 C below zero to the most elevated operational temperatures. Ability to filter infinitely small metallic particles and trap a greater quantity of harmful larger contaminants, in virtue of the special micro-porosity filtering media itself and its high capacity. Technical Characteristics High air flow Multilayer long fi bre cotton gauze, oiled, and sandwiched between two epoxy-coated aluminium wire screens. Encased in a polyurethane frame, 30 ShA, insuring an excellent seal Washable and reusable Pre-hardened carbon steel springs for original clutch, with high yield strength, galvanically treated for extended protection. The different colouring indicates the load capacity of each spring series. The spring kit permits up to a 500 rpm clutch engagement with 150 rpm increments per spring type. Rear Brake Disc Technical Characteristics Stainless steel disk, laser cut, hardened and surface machined. Profile designed using CAD to insure complete scraping of the brake pad, the elimination of brake dust, and the removal of water and mud during braking. Surface area doubled to lower the disk s working temperature.

4 Twin Cylinder 4-stroke 560 cc.

Super T-Max Twin Cylinder 4-stroke 560 cc. Over 15% increase in power Extreme reliability. Made in Italy Technology.

and thermal integrity. Of particular interest are the pistons, which are forged using a special alloy, analysed, and designed to withstand the working stresses due to extended use.

5 Super T-Max Twin Cylinder 4-stroke 560 cc. Over 15% increase in power Extreme reliability. Made in Italy Technology. Designed and manufactured in the Calderara di Reno, Italy facility Malossi s engineering staff gave special attention in all phases, from design to manufacturing, as with all the products displaying this trademark. Yamaha s clean design single block, twin cylinder was modifi ed by Malossi with signifi cant changes and updates that allowed a substantial bore increase without compromising the original mechanical and thermal integrity. Of particular interest are the pistons, which are forged using a special alloy, analysed, and designed to withstand the working stresses due to extended use. Nothing was left to chance, from the gaskets to the lightweight, taper bore, high alloy steel gudgeon pin to the chromed plated and gas nitride steel piston rings. Every detail is a precious contribution in creating a very exclusive cylinder/piston set: a product for a discerning and well-informed customer! Technical Characteristics Bore: ø 70 mm Stroke: 73 mm Displacement: 560 cc Compression Ratio: 1:12 Max RPM Twin Cylinder Single Block: Special Al-Si-Cu alloy, hardened and stress relieved Cylinder liners: Cermetal (Ni-Ca-Sil) coated and machined with extreme precision in our state of the art work cells Cross-honed at 110 /130 Ø 70 forged pistons pin Ø 15 with 3 piston rings Ø 70 forged pistons pin Ø 15 with 3 piston rings: Special Al-Si-Cu alloy, hardened, shaped crown with valve reliefs, racing design, reinforced and lightened with constant wall thickness. Ø 66 forged pistons pin Ø 15 with 3 piston rings high compression for original cylinder Technical Characteristics Piston Rings (3): 1st - Compression Ring: Chrome plated steel. 2nd - Intermediate Ring: Phosphate coated steel. 3rd - Oil Control Ring: 3-piece oil ring, (chrome plated steel rails, plus spring).

ORIGINAL VEHICLE ø 66 MALOSSI PISTONS HIGH COMPRESSION DOUBLE POWER CAMS MAXI WILD LION Homologated TWIN CYLINDER MALOSSI ø 70 DOUBLE POWER CAMS MAXI WILD LION Homologated POWER CV kw 52,0 38,2 50,0

6 ORIGINAL VEHICLE ø 66 MALOSSI PISTONS HIGH COMPRESSION DOUBLE POWER CAMS MAXI WILD LION Homologated TWIN CYLINDER MALOSSI ø 70 DOUBLE POWER CAMS MAXI WILD LION Homologated POWER CV kw 52,0 38,2 50,0 36,8 48,0 35,3 46,0 33,8 44,0 32,3 42,0 30,9 40,0 29,4 TESTS PERFORMED ON YAMAHA T MAX 500 [4B5] 2008 VERSION Max Power [CV]=40,139 Max Torque [Nm]=42,750 Max Power [CV]=45,420 Max Torque [Nm]=45,436 Max Power [CV]=51,455 Max Torque [Nm]=50,446 TORQUE Kgm Nm 13,25 130,00 12,67 124,35 12,10 118,70 11,52 113,04 10,94 107,39 10,37 101,74 9,79 96,09 9,22 90,43 38,0 27,9 8,64 84,78 36,0 26,5 8,06 79,13 34,0 25,0 7,49 73,48 32,0 30,0 23,5 22,1 6,91 6,34 5,76 67,83 62,17 56,52 28,0 20,6 5,18 50,87 26,0 19,1 4,61 45,22 24,0 17,6 4,03 39,57 22,0 16,2 3,46 33,91 20,0 14,7 2,88 28,26 18,0 16,0 13,2 11,8 2,30 1,73 22,61 16, RPM

Power Cams Camshafts are the most critical timing component in a 4-Cycle engine.

intake valves and also evacuating the exhaust gases by opening and closing the exhaust valves.

compression pistons and original cylinder or an exponential increase in power if matched with Malossi s 560 cc big bore twin cylinder set.

In fact, fi rst and second series, if equipped with Malossi s Double Power Cams, can produce noticeable power increases.

The manufacturing process was achieved by our engineering department s scrupulous requirements, starting with the material selection to the

7 Power Cams Camshafts are the most critical timing component in a 4-Cycle engine. The camshafts, in fact, are assigned the tasks of controlling the air/fuel mixture in the combustion chamber by opening and closing the intake valves and also evacuating the exhaust gases by opening and closing the exhaust valves. Malossi s Double Power Cams are fi ne-tuned to generate an optimum and progressive power increase if matched with Malossi s high compression pistons and original cylinder or an exponential increase in power if matched with Malossi s 560 cc big bore twin cylinder set. Malossi has thought of both carburetted and electronic fuel injected scooters. In fact, fi rst and second series, if equipped with Malossi s Double Power Cams, can produce noticeable power increases. Malossi s Double Power Cams result from long and meticulous engine testing with our in-house dyno. The manufacturing process was achieved by our engineering department s scrupulous requirements, starting with the material selection to the high precision machining to the heat and chemical treating and fi nally to quality inspection and assembly. Malossi S.p.A, always providing the highest quality service. Super T-MaxDouble Double Power Cams Intake valve camshaft Exhaust valve camshaft Specifications Made of high alloy steel, casehardened, gas nitride, and ground with redesigned, high lift and re-profi led lobes.

MULTIVAR The variator is supplied with two roller sets and two spacers allowing to alternate the scooter s gearing

With the racing experience acquired from the Maxi Scooter 500 Trophy racing series, Malossi Trophy Series top class,

Technical specifications Increased displacement to improve low-gear performance.

Ground steel bushing lubricated with mineral based grease MRG grease Malossi New one-piece rollers with a better

MHR Grease MULTIVAR The meticulous attention given to the roller ramps by Malossi s technical staff, guarantee an optimal

8 MULTIVAR The variator is supplied with two roller sets and two spacers allowing to alternate the scooter s gearing according to rider preference while sustaining the original variator maintenance interval. With the racing experience acquired from the Maxi Scooter 500 Trophy racing series, Malossi Trophy Series top class, Malossi s engineers, in collaboration with the riders, fine tuned the New Generation Mutivar 2000 MHR variator. Technical specifications Increased displacement to improve low-gear performance. Modified roller guides to allow greater operational linearity while maintaining maximum power. Ground steel bushing lubricated with mineral based grease MRG grease Malossi New one-piece rollers with a better performing compound. MHR Grease MULTIVAR The meticulous attention given to the roller ramps by Malossi s technical staff, guarantee an optimal scooter performance, both in standing and motoring accelerations while maintaining normal engine speed, a vehicle prerequisite for a scooter developed for predominately TOURING- SPORT use. Technical specifications Ground steel bushing lubricated with mineral based grease MRG grease Malossi New one-piece rollers with a better performing compound.

Super T-Max VENTILVAR 2000 The new fixed half-pulley features a diamond finish of the beltside pulley

This component completes the Multivar and renders it unparalleled!

diamond finished aluminium, riveted to guarantee the highest rigidity.

Developed expressly to operate with our high powered cylinder and head kits, our MHR variators, and

9 Super T-Max VENTILVAR 2000 The new fixed half-pulley features a diamond finish of the beltside pulley surface and a redesigned working angle to further increase the gearing range. This component completes the Multivar and renders it unparalleled! TORQUE DRIVER Malossi s mobile driven split pulley was developed utilizing its racing department s many years of experience. The spiral section is made of the finest steel; nitride surface hardened, the pulley is made of diamond finished aluminium, riveted to guarantee the highest rigidity. The spiral section s special form was fine tuned to maintain constant engine speed at peak horsepower. Developed expressly to operate with our high powered cylinder and head kits, our MHR variators, and Malossi Kevlar Belts to exploit the full potential of the appreciable torque and horsepower increase of your scooter. VARIABLE-SPEED DRIVE ADJUSTER SPRING Silicon-steel springs with high carbon content, heat-treated, dynamically balanced, kiln painted and designed and calculated for each specific application. Load [N] + 30 % + 13 % + 7 % Rigidy compared to the original - 39 % R W Y G0 ORIGINAL SPRING Legenda

Technical features Oil-gas suspension with pressurized nitrogen chamber; Hydraulic adjustment in expansion; Patented adjustment of the spring pre-load; Adjustment of the vehicle setting; Stroke 48

Adjustment system of the scooter setup, with fi t shock absorber.

shock absorber was born out of the cooperation between Malossi designers and Paioli manufacturer.

ensure an excellent driving comfort both for sports and touristic use, with or without passenger on board.

In order to ensure its reliability, we have fi rst developed various prototypes, then strictly tested for many weeks on specifi c benches, before being checked on the road and on the tracks.

absorb the harshness of the ground. 2) Spring pre-load allows to fi t the vehicle while driving according to the passengers weight.

10 Technical features Oil-gas suspension with pressurized nitrogen chamber; Hydraulic adjustment in expansion; Patented adjustment of the spring pre-load; Adjustment of the vehicle setting; Stroke 48 mm; Outside wrapper in ergal 55 with cobalt blue anodic oxidation; Adjustable forged connection in ergal 55 with anodic oxidation; Connection made out of treatment in ergal 55 with anodic oxidation; Adjustment system of the scooter setup, with fi t shock absorber. Extension braking calibration knob Whellbase adjusting Patented oil-gas shock absorber Spring pre-load hydraulic regulation screw REAR SHOCK ABSORBER This superlative, compact and very light rear shock absorber was born out of the cooperation between Malossi designers and Paioli manufacturer. A real oil-gas suspension with variable setting and extension adjusting, compensated for a pressurized nitrogen chamber, provided with a special patented spring pre-load adjusting system in order to ensure an excellent driving comfort both for sports and touristic use, with or without passenger on board. The project has been studied for long by the technicians of both companies who, already used to team work, joined their own experiences to create an innovative suspension. In order to ensure its reliability, we have fi rst developed various prototypes, then strictly tested for many weeks on specifi c benches, before being checked on the road and on the tracks. The versatility of this suspension turned out to be astonishing thanks to three new adjustment systems, which enhance its use both on the road and on tracks: 1) Extension adjustment in order to absorb the harshness of the ground. 2) Spring pre-load allows to fi t the vehicle while driving according to the passengers weight. This suspension uses a special patented system, unique in the world, which allows to make all the necessary adjustments by simply using a ring spanner on a screw placed in the head of the shock absorber, easily accessible. 3) System of setting variation as regards the behavior in bends, whether you use the vehicle for sport. The peculiarity of this project actually consists in the possibility to make all the necessary adjustments in a quick and effi cient way, without removing the shock absorber from the vehicle. Nothing has been neglected while studying the project! The reduction of the weight, for example, was one of our priority aim: this is the reason why most of the components are manufactured in ergal, forged, extruded and made out of solid, thanks to the best present technologies. The result of such a meticulous design allowed to achieve a weight saving of about 20%, in details, our RS24 suspension weights grams instead of the grams of the original one. We think that this is an important achievement towards that sport concept of our Super T-Max Malossi! RS24 Malossi for YamahaT-Max: a Made in Italy excellence, a patent to be proud of!

11 Super T-Max T MAX (carb.) 2001->2003 YAMAHA T MAX ie 2004->2007 T MAX ie 2008-> 500 4T 500 4T 500 4T TWIN CYLINDER 4-STROKE 560 cc. Ø (*) ALUMINIUM ø 66 FORGED PISTONS pin 15 with 3 piston rings HIGH COMPRESSION FOR ORIGINAL CYLINDER DOUBLE POWER CAMS CAMSHAFT MULTIVAR 2000 VARIATOR OVER RANGE MULTIVAR 2000 MHR VARIATOR X KEVLAR BELT BELT VENTILVAR 2000 HALF-PULLEY B B B ALSO FOR ORIGINAL VARIATOR TORSION CONTROLLER TORQUE DRIVER CORRECTEUR DE COUPLE VARIABLE-SPEED DRIVE ADJUSTER SPRING + 30 % R R R0 VARIABLE-SPEED DRIVE ADJUSTER SPRING + 13 % W W W0 VARIABLE-SPEED DRIVE ADJUSTER SPRING + 7 % Y Y Y0 VARIABLE-SPEED DRIVE ADJUSTER SPRING - 39 % G G G0 RACING CLUTCH SPRINGS FOR ORIGINAL CLUTCH MAXI WILD LION HOMOLOGATED EXHAUST SYSTEM (SJ06 var.1 ver.1/2/3/5/6/7 - var.2 ver. 8/9/10) REAR SHOCK ABSORBER PATENTED OIL-GAS SHOCK ABSORBER SUSPENSION BRACKET SHOCK ABSORBER BRACKET KIT W BOX FILTER AIR FILTER RED CHILLI OIL FILTER OIL FILTER WHOOP DISC COUPLE (SINGLE) FRONT BRAKE DISCS WHOOP DISC REAR BRAKE DISC BRAKE PADS (FRONT) (FRONT) - MHR SYNT (REAR) RACING BRAKE LINE KITS COVERS for rear-view mirror slots CHROMED C C0 - BLACK N N0 - MHR SCREEN (*) ONLY FOR vehicles WITH HYDRAULIC CHAIN TENSIONER:

company will intensify during the year 2010, since MALOSSI T-MAX CUP Trophy was born.

The Trophy provides two racing categories named Stock and Open.

camshaft. You will be also allowed to work on the cylinder head ports, therefore giving mechanics a free hand.

12 Super T-Max trofei.malossi.com After the success of the partnership between Yamaha and Malossi with their R-125 Cup Trophy, the co-operation between the brand of the three tuning forks and the Bolognese company will intensify during the year 2010, since MALOSSI T-MAX CUP Trophy was born. This trophy has its origin in Malossi Maxi Scooter 500 Trophy, which will concentrate from this year on exclusively on the Yamaha best seller, the most appreciated T-Max. The Trophy provides two racing categories named Stock and Open. The Stock category is reserved for all T-max injection models with basic tuning, while the Open category provides the use of the new Malossi 560 cc cylinder kit as well as Malossi camshaft. You will be also allowed to work on the cylinder head ports, therefore giving mechanics a free hand. Malossi T-Max Cup Trophy is a national championship consisting of five races on the following tracks: Varano, Castelletto di Branduzzo, Binetto, Vallelunga and Adria. This year too you can take advantage of the participation premium: those who take part in all the races and comply with their ORGANIZATION: rules will get a refund for registration RACE SERVICE MALOSSI SRL costs, racing and paint kit as well as Fax Cell Malossi official racing suit. race@raceservice.com MOTOR OIL 4T RACING RX 4T RACING Synt Engine OIL (SAE 5W-40) RX 4T RACING Synt Engine OIL (SAE 10W-50) * GB* GB - 10/2010

V4 HEAD Monumental Achievement Malossi

V4 HEAD Monumental Achievement Malossi Monumental Achievement Malossi The first head for all Piaggio scooters that have a 4-stroke, liquid cooled engine with the following displacements: 125*cc, 180*cc,