Page 1 MOSTER 185 EFI Maintenance manual Release V1/2024. Valid for MY24 version.
Page 2 Moster 185 EFI - Maintenance manual - V1/2024...
Page 3: Table Of Contents
3.4.7 Fuel tank pipes disassembly 3.4.8 Fuel tank pipes assembly 3.4.9 Fuel microfilter disassembly 3.4.10 Fuel microfilter maintenance 3.4.11 Fuel microfilter assembly 3.4.12 Vittorazi paper filter disassembly 3.4.13 Vittorazi paper filter maintenance Moster 185 EFI - Maintenance manual - V1/2024...
Page 4 3.8.2 Air rotary valve assembly 3.9 Reed valve 3.9.1 Reed valve disassembly 3.9.2 Reed valve maintenance 3.9.3 Reed valve assembly 3.10 Battery 3.10.1 Electric starter 60A fuse disassembly 3.10.2 Electric starter 60A fuse assembly 3.11 Gaskets Moster 185 EFI - Maintenance manual - V1/2024...
Page 5 3.16.2 Belt disassembly 3.16.3 Bell, clutch disassembly 3.16.4 Transmission maintenance 3.16.5 Bell, clutch assembly 3.16.6 Pulley assembly 3.16.7 Belt insertion 3.16.8 Belt tensioning 3.17 Piston, cylinder, head 3.17.1 Piston, cylinder, head disassembly Moster 185 EFI - Maintenance manual - V1/2024...
Page 6 3.17.2 Piston, cylinder, head maintenance 3.17.3 Piston, cylinder, head assembly 3.18 Crankcase 3.18.1 Crankcase disassembly 3.18.2 Crankcase maintenance 3.18.3 Crankcase assembly 3.19 Tightening values Moster 185 EFI - Maintenance manual - V1/2024...
Page 7: Introduction
The professional manual includes: technical descriptions of the maintenance phase and reference values. All the components of Vittorazi Motors are checked and tested in a process of industrial quality control before the assembling. Then by sampling the complete motors are checked to assure the functionality of all the parts through a complete test of twenty minutes on the bench.
Page 8 Reading tips: Attention, danger, risk Any situation or condition which may result in a serious danger Recommendation, warning, important advice Moster 185 EFI - Maintenance manual - V1/2024...
Page 9: Be Careful! Read It Completely
• Vittorazi Motors and its distributors decline any direct or indirect responsibility related to this kind of activity. By using a new engine, the owner agrees that these terms and conditions have been accepted at the time of purchase of the product.
Page 10 Proceed at reduced power and once on the ground contact your dealer LiPo batteries are high-tech products but potentially dangerous to property, animals or people, especially if used improperly or without experience. Moster 185 EFI - Maintenance manual - V1/2024...
Page 11: Maintenance
Any procedure of installation, maintenance and/or repair of the products must be carried out exclusively with the original Vittorazi Motors parts and tools specified by Vittorazi, in compliance with the specifications contained in the user, installation and/or maintenance manual of the products;...
Page 12: Maintenance Schedule
Lubricate with WD-40 Note: 1) or after a year, whichever comes first. 2) or after 500 cycles, whichever comes first. 3) or after 300 charging cycles or 3 years, whichever comes first. Moster 185 EFI - Maintenance manual - V1/2024...
Page 13 (tightening) Spark plug Spark plug cap Airbox Snaplock Airbox Airbox sponge and sleeve Fuel injector Fuel injector connector Fuel injector test Pump value min test The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 14 Fuel injector pipes Fuel tank pipes Rubber mountings (FIU, engine, exhaust) ECU signal wiring ECU supply wiring Electric starter wiring RJ-45 cable CHT sensor EGT sensor Battery The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 15 �� Exhaust manifold with springs Soundproofing material silencer Rubber silencer fixing washers Gaskets (cylinder, Air Rotary Valve, reed valve, exhaust, silencer) Piston Piston roller bearing The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 16 Head and cylinder O-ring head Oil seal carter case Crankshaft bearings Crankshaft Belt Reduction bearings Centrifugal clutch Clutch bell Moster 185 EFI - Maintenance manual - V1/2024...
Page 17: Spark Plug
Distance between the spark plug electrodes: 0,7 mm (new spark plug) 0,9 mm (worn spark plug limit). Values Spark plug: 25 Nm. 3.2.1 Spark plug disassembly Disconnect the spark plug cap. Unscrew the spark plug. Moster 185 EFI - Maintenance manual - V1/2024...
Page 18: Spark Plug Maintenance
The new spark plug for the engine must be of the same type and rating as the one to be replaced (ACC090). Check the ignition cable: there must be no cuts or cracks, otherwise replace the ignition coil (including ignition cable). Moster 185 EFI - Maintenance manual - V1/2024...
Page 19: Spark Plug Assembly
The distance between the electrodes of the new spark plug must be 0,7 mm, otherwise adjust. Insert the spark plug into the head and tighten with the torque shown in the figure. 25 Nm Connect the spark plug cap. Moster 185 EFI - Maintenance manual - V1/2024...
Page 20 Once the spark plug cap is inserted check that the rubber cap is in contact with the cooling shroud. Moster 185 EFI - Maintenance manual - V1/2024...
Page 21: Spark Plug Cap Disassembly
3.2.4 Spark plug cap disassembly Disconnect the spark plug cap. Remove the rubber cap from the spark plug cap. Moster 185 EFI - Maintenance manual - V1/2024...
Page 22: Spark Plug Cap Maintenance
Check that the spark plug cap is an NGK spark plug cap (cod. MI031a). The Moster 185 EFI uses a different spark plug cap than other Vittorazi engines. Apply a small amount of silicone spray (recommended LOCTITE LB 8021) to the tip of the cable to facilitate the insertion of the spark plug cap.
Page 23 Once screwed in all the way, check that the two bodies are firmly joined by pulling the cable and spark plug cap. Insert the rubber cap on the spark plug cap. Moster 185 EFI - Maintenance manual - V1/2024...
Page 24 Connect the spark plug cap on the spark plug. Once the spark plug cap is inserted check that the rubber cap is in contact with the cooling shroud. Moster 185 EFI - Maintenance manual - V1/2024...
Page 25: Airbox
Snaplock (MP093d). 25 h Sleeve with filter (AT093a). 100 h or 1 year Components to replace Not required. Special tools Clamp screw: 2,5 Nm. Values 3.3.1 Airbox disassembly Unhook the safety strap. Moster 185 EFI - Maintenance manual - V1/2024...
Page 26 Loosen the screw of the clamp securing the sleeve to the air rotary valve and remove the airbox. Fold the sleeve inwards and remove it from the airbox. Remove the Snaplock. Moster 185 EFI - Maintenance manual - V1/2024...
Page 27: Airbox Maintenance
(2) with a product suitable for cleaning rubber (the sleeve is made up of a mixture of NBR and PVC). Check the integrity of the airbox. Check the sleeve groove (the photo shows a damaged groove). Moster 185 EFI - Maintenance manual - V1/2024...
Page 28 If the above components are damaged, replace them immediately. For routine maintenance, follow the table. Use extreme caution when checking, as failure to replace damaged components can lead to detachment of the airbox and impact with the propeller. Moster 185 EFI - Maintenance manual - V1/2024...
Page 29: Airbox Assembly
Insert the sleeve into the airbox. Insert the Snaplock. Connect the sleeve of the airbox to the air rotary valve (1), after having inserted it rotate the airbox to fix the Snaplock (2). Moster 185 EFI - Maintenance manual - V1/2024...
Page 30 Attach the safety strap to the bracket between the vibration damper and the ignition coil, ensuring that the strap is tightened firmly. After installation, check that there is no relative movement between the rubber sleeve and the Airbox connector. Moster 185 EFI - Maintenance manual - V1/2024...
Page 31: Fuel Injection Line
In case of occlusion of a component inside the Fuel Box Unit (FBU), it will be necessary to replace the entire Full Integrated Unit (FIU) and ship the defective one to the Vittorazi headquarters. Moster 185 EFI - Maintenance manual - V1/2024...
Page 32: Fuel Injector Test
Before disassembling the injector, remove the airbox (see chapter 3.3 Airbox). Unscrew the injector flange screw M5x12 (1). Gently extract the injector (2) from its seat on the air rotary valve (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 33 2. Decrease the “Pump Value Min” by pressing the “Enter” and “-” keys simultaneously. Reduce it by 0.1 to obtain a decrease of about 2 cc in the result of the “Injector test min”. Moster 185 EFI - Maintenance manual - V1/2024...
Page 34 Reduce it by 0.1 to obtain a decrease of about 2 cc in > 42 cc the result of the “Injector Test Max”. 1.2. For customers: Contact Vittorazi. Insert the injector (2) in its seat on the air rotary valve (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 35 While tightening the screw M5x12 (1), control that the injector remains coaxial with its seat to avoid any bend on the fuel pipes. 6,5 Nm Insert the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 36: Fuel Injector Disassembly
Before disassembling the injector, remove the airbox (see chapter 3.3 Airbox) and switch off the battery. Unscrew the injector flange screw M5x12 (1). Gently extract the injector (2) from its seat on the air rotary valve (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 37 However, when removing the injector from its seat, be careful not to bend and pull the fuel hoses. Extract the connector (4) by carefully turning it left and right while pulling. Moster 185 EFI - Maintenance manual - V1/2024...
Page 38 Extract the injector clip (5). Extract the injector (2) from the flange (6). Injector flange may be full of fuel, place a bowl underneath to catch leaking fuel. Moster 185 EFI - Maintenance manual - V1/2024...
Page 39: Fuel Injector Maintenance
Apply a small amount of silicon grease (Recommended FP Silicompound 225 - Silicon based grease + PTFE) on the injector O-rings (7) and insert the injector (2) in the flange (6) seat. Insert the injector clip (5) correctly as show in the figures. Moster 185 EFI - Maintenance manual - V1/2024...
Page 40 Control the position of the security ring (8) in the connector (4). Apply a small amount of contact grease (recommended ELECTROLUBE contact treatment grease SGB - 2GX) on the connector and the injector contacts. Moster 185 EFI - Maintenance manual - V1/2024...
Page 41 Insert the injector (2) in its seat on the air rotary valve (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 42 While tightening the screw M5x12 (1), control that the injector remains coaxial with its seat to avoid any bend on the fuel pipes. 6,5 Nm Insert the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 43: Fuel Injector Pipes Disassembly
The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Remove the M6 nut (1) and the M6 F10 cable clamp (2). Remove the M6 nut (5) and the M6 F10 cable clamp (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 44 Do not use pliers or screwdrivers to extract the injector fuel supply pipe, this could cause damage to the pipe or the pipe connector Do not unscrew the pipe connector; it is locked with high-strength threadlocker. Turning it could damage the connector itself or the hydraulic system. Moster 185 EFI - Maintenance manual - V1/2024...
Page 45 Repeat this operation with the injector fuel return pipe (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 46 Do not unscrew the pipe connector; it is locked with high-strength threadlocker. Turning it could damage the connector itself or the injector flange. Repeat this operation with the injector fuel supply pipe (8). Moster 185 EFI - Maintenance manual - V1/2024...
Page 47: Fuel Injector Pipes Disassembly
Insert the injector fuel supply (8) and return (10) pipes on the injector fittings (16, 17) The connection position of the injector fuel supply (8) and return (10) pipes can be interchanged indifferently. By default, they are connected as shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 48 Screw the external ring (15) of the injector fuel supply pipe (8) until it is aligned with the tip of the internal cylinder. Repeat this operation with the external ring (14) of the injector fuel return pipe (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 49 (9, 11) and to avoid damaging the tubes and twisting them. Screw the external ring (11) of the injector fuel return tube (10) until it is aligned with the tip of the internal cylinder. Moster 185 EFI - Maintenance manual - V1/2024...
Page 50 (3) in the position shown in the figure and tighten with the torque shown in the figure. Before tightening, control that the injector fuel pipes are not bended or pulled and make sure to block the cable clamp to prevent rotation while tightening. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 51 Before tightening, control that the signal cable is not bended or pulled and make sure to block the cable clamp to prevent rotation while tightening. 10 Nm Insert the fuel tubes (7) on the 2 cable supports. Moster 185 EFI - Maintenance manual - V1/2024...
Page 52: Fuel Tank Pipes Disassembly
The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Remove the tank fuel return pipe (19) and the tank fuel supply pipe (21). Remove the tank fuel return pipe (19) and the tank fuel supply pipe (21). Moster 185 EFI - Maintenance manual - V1/2024...
Page 53 Remove the M10 nut (24) from the tank supply pass-through fitting (22) and remove the fuel pipe inside the tank (26). Remove the tank supply pass-through fitting (22) from the pipe (26). Moster 185 EFI - Maintenance manual - V1/2024...
Page 54: Fuel Tank Pipes Assembly
Carry out the following operations in a clean and dust-free environment. The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Insert the Vittorazi paper filter (27) on the pipe (26). Moster 185 EFI - Maintenance manual - V1/2024...
Page 55 Insert the tank supply pass-through fitting (22) with the O-ring (25) on the other side of the pipe (26). Place the pipe inside the tank and fix the tank supply pass-through fitting (22) with the M10 nut (24). Moster 185 EFI - Maintenance manual - V1/2024...
Page 56 (21) on the tank supply pass-through fitting (22). Insert the tank fuel return pipe (19) to the upper fitting of the FBU (18) and the tank fuel supply pipe (21) on the lower fitting of the FBU (20). Moster 185 EFI - Maintenance manual - V1/2024...
Page 57: Fuel Microfilter Disassembly
Do not use pliers or screwdrivers to extract the injector fuel supply tube, this could cause damage to the tube or the internal cylinder Do not unscrew the internal cylinder; it is locked with high-strength threadlocker. Turning it could damage the cylinder itself or the hydraulic system. Moster 185 EFI - Maintenance manual - V1/2024...
Page 58 Remove the external microfilter cap (3). Check that the FBU is equipped with an anti-rotation system, otherwise it is necessary to lock the other side of the microfilter capsule with a 12 mm wrench to prevent rotation. Moster 185 EFI - Maintenance manual - V1/2024...
Page 59 Carefully remove the O-ring (4) from the microfilter cap (3). Pay attention not to damage or introduce dirt inside the microfilter cap (3). Remove the microfilter (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 60 Carefully remove the O-ring (6). Pay attention not to damage or introduce dirt inside the microfilter seat. Moster 185 EFI - Maintenance manual - V1/2024...
Page 61: Fuel Microfilter Maintenance
The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Replace the O-rings (4, 6) and the microfilter (5) each time they are disassembled. Insert the O-ring (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 62 Place the O-ring (4) inside the external microfilter cap (3) using the microfilter (5) to push it in the right position. Insert the microfilter (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 63 0.3 Nm Check that the FBU is equipped with an anti-rotation system, otherwise it is necessary to lock the other side of the microfilter capsule with a 12 mm wrench to prevent rotation. Moster 185 EFI - Maintenance manual - V1/2024...
Page 64 (2) and to avoid damaging the tube and twisting it. Screw the external ring (2) of the injector fuel supply tube (1) until it is aligned with the tip of the internal cylinder. Moster 185 EFI - Maintenance manual - V1/2024...
Page 65: Vittorazi Paper Filter Disassembly
The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Extract the Vittorazi paper filter (7) from the fuel tank. Remove the Vittorazi paper filter (7). Moster 185 EFI - Maintenance manual - V1/2024...
Page 66: Vittorazi Paper Filter Maintenance
The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Replace the Vittorazi paper filter (7) each time they are disassembled. Insert the Vittorazi paper filter (7). Moster 185 EFI - Maintenance manual - V1/2024...
Page 67 Place the Vittorazi paper filter (7) inside the tank. Moster 185 EFI - Maintenance manual - V1/2024...
Page 68: Full Integrated Unit (Fiu)
Vittorazi-approved and tested components, which are installed by competent personnel and also to facilitate the replacement of the entire FIU. Breach of the seals invalidates the warranty and relieves dealers and Vittorazi of any responsibility. Moster 185 EFI - Maintenance manual - V1/2024...
Page 69: Fiu Disassembly
ECU. Make sure the return pipe (2) is connected to the fuel tank to collect the fuel contained inside the fuel line. Wait until air comes out from the fuel return pipe (2) and turn off the ECU. Moster 185 EFI - Maintenance manual - V1/2024...
Page 70 Remove the return tank pipe (2). Protect the tank supply and return FBU fittings with caps to prevent the entry of impurities inside the fuel line. Moster 185 EFI - Maintenance manual - V1/2024...
Page 71 Remove the 2 screws M4x16 (3) and the 2 self-locking nuts M4 (4). Remove the screw M5x10 (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 72 Remove the screw M4x6 (7). Remove the screw M4x6 (9). Moster 185 EFI - Maintenance manual - V1/2024...
Page 73 Remove the screw M4x6 (11). Remove the power wiring connector (13) and the signal wiring connector (14). Moster 185 EFI - Maintenance manual - V1/2024...
Page 74 Do not unscrew the pipe connector; it is locked with high-strength threadlocker. Turning it could damage the connector itself or the hydraulic system. Repeat this operation with the injector fuel return tube (17). Moster 185 EFI - Maintenance manual - V1/2024...
Page 75 Protect the injector supply and return FBU fittings with caps to prevent the entry of impurities inside the fuel line. Moster 185 EFI - Maintenance manual - V1/2024...
Page 76 Remove the 4 screws M4x6 (19). Remove the FIU (20). Moster 185 EFI - Maintenance manual - V1/2024...
Page 77: Fiu Maintenance
3.5.3 FIU assembly Carry out the following operations in a clean and dust-free environment. The entry of impurities into the hydraulic circuit can impair the functioning of the circuit components. Place the FIU (20). Moster 185 EFI - Maintenance manual - V1/2024...
Page 78 PTFE) to the tubes, taking care not to get it inside the tubes, to facilitate the sliding of the external rings (16, 18) and to avoid damaging the tubes and twisting them. Moster 185 EFI - Maintenance manual - V1/2024...
Page 79 Screw the external ring (18) of the injector fuel return tube (17) until it is aligned with the tip of the pipe connector. Repeat this operation with the external ring (16) of the injector fuel supply tube (15). Moster 185 EFI - Maintenance manual - V1/2024...
Page 80 Fix the sensors supply cable and the battery cable on the FBU with the M5 F6 cable clamp (6) and the screw M5x10 (5) in the position shown in the figure and tighten with the torque shown in the figure. 5 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 81 Fix the relay supply cable on the FBU with the 3 mm plastic cable clamp (10) and the screw M4x6 (9) in the position shown in the figure with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 0.6 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 82 0.6 Nm Insert the 2 screws M4x16 (3) with the 2 self-locking nuts M4 (4) and tighten with the torque shown in the figure. 3 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 83 Insert the supply and return tank pipes (1, 2). Perform an injector test min and an injector test max and adjust the pump value min and pump value max according to the results (See chapter 3.4.1 Fuel Injector test). Moster 185 EFI - Maintenance manual - V1/2024...
Page 84: Wirings
Screw M4x12: 4 Nm. Values Screws M3x25: 0.4 nm. Screw M4x6: 0.6 Nm. *Always replace it when disassembled. 3.6.1 ECU Signal wiring disassembly Remove the screw M6x10 (1) and the M6 F8 cable clamp (2). Moster 185 EFI - Maintenance manual - V1/2024...
Page 85 Remove the nut M6 (3) and the M6 F8 cable clamp (4). Remove the screw M4x12 (5) and the M5 F5 cable clamp (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 86 Remove the screw M4x12 (7) and the M5 F6 cable clamp (8). Remove the Air rotary valve connector (9) by lifting the lever while pulling. Moster 185 EFI - Maintenance manual - V1/2024...
Page 87 Extract the fuel injector (see chapter 3.4.2 fuel injector disassembly) and remove the fuel injector connector (10) by carefully turning it left and right while pulling. Remove the coil connector (11). Moster 185 EFI - Maintenance manual - V1/2024...
Page 88 Remove the signal cable connector (12) by pushing the lever while pulling. Moster 185 EFI - Maintenance manual - V1/2024...
Page 89: Ecu Signal Wiring Assembly
Fix the signal cable with the M6 F8 cable clamp (2) and the screw M6x10 (1) on the steel bracket (14) in the position shown in the figure and tighten with the torque shown in the figure. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 90 (17) with the screw M4x12 (5) on the flange (18) with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 4 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 91 Control the position of the security ring (20) in the connector (10). Apply a small amount of contact grease (recommended ELECTROLUBE contact treatment grease SGB - 2GX) on the connector and the injector contacts. Moster 185 EFI - Maintenance manual - V1/2024...
Page 92 Insert the fuel injector connector (10) and insert the fuel injector on its seat on the air rotary valve (see chapter 3.4.4 Fuel injector assembly). Insert the air rotary valve connector (9). Moster 185 EFI - Maintenance manual - V1/2024...
Page 93: Ecu Supply Wiring Disassembly
3.6.3 ECU Supply wiring disassembly Remove the screw M5x10 (1) and the M5 F6 cable clamp (2). Remove the screw M4x6 (3) and the 5 mm plastic cable clamp (4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 94 Remove the screw M4x6 (5) and the 3 mm plastic cable clamp (6). Remove the screw M4x6 (7) and the 3 mm plastic cable clamp (8). Moster 185 EFI - Maintenance manual - V1/2024...
Page 95 Remove the outer relay supply connector (9) by pressing the internal lever with a screwdriver while pulling. Repeat this operation with the inner relay supply connector (10). Remove the 2 screws M3x25 (11) from the sensors support. Moster 185 EFI - Maintenance manual - V1/2024...
Page 96 Extract the 2 rubber blocks (12). Moster 185 EFI - Maintenance manual - V1/2024...
Page 97 Disconnect the EGT (13) and the CHT (14) sensor connector. Extract the ECU supply connector (15). Moster 185 EFI - Maintenance manual - V1/2024...
Page 98: Ecu Supply Wiring Assembly
3.6.4 ECU Supply wiring assembly Connect the EGT (13) and the CHT (14) sensor connector. Insert the cables inside the rubber blocks (12) following the scheme shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 99 Insert the rubber blocks (12) inside their seats in the sensors support as shown in the figure. Insert the 2 screws M3x25 with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 0.4 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 100 Insert the ECU supply connector (15) on the ECU connector (16). Insert the outer relay supply connector (9) (with black spot) on the external relay plug with the internal lever of the faston connector facing inwards Moster 185 EFI - Maintenance manual - V1/2024...
Page 101 Fix the relay supply cable (17) on the FBU (18) with the 3 mm plastic cable clamp (6) and the screw M4x6 (5) in the position shown in the figure with threadlocker (recommended Loxeal 55- 03/Loctite 243) and tighten with the torque shown in the figure. 0.6 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 102 Fix the sensors supply cable (19) and the battery cable (20) on the FBU (18) with the M5 F6 cable clamp (2) and the screw M5x10 (1) in the position shown in the figure and tighten with the torque shown in the figure. 5 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 103: Electric Starter Wiring Disassembly
3.6.5 Electric starter wiring disassembly Remove the plastic cable clamp (1). Carefully disconnect the 2 faston connectors (3, 4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 104 Remove the screw M6x10 (5) and the M6 F8 cable clamp (6). Remove the screw M6x10 (7) and the M6 F8 cable clamp (8). Moster 185 EFI - Maintenance manual - V1/2024...
Page 105 Carefully remove the starter power cable that goes from the relay to the starter (11). Repeat this operation with the starter power cable that comes from the battery to the relay (12). Moster 185 EFI - Maintenance manual - V1/2024...
Page 106: Electric Starter Wiring Assembly
Fix the starter supply cable (13) on the steel bracket (14) with the M6 F8 cable clamp (10) and the screw M6x10 (9) in the position shown in the figure and tighten with the torque shown in the figure. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 107 Fix the starter supply cable (13) to the flange (15) with the M6 F8 cable clamp (6) and the screw M6x10 (5) in the position shown in the figure and tighten with the torque shown in the figure. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 108 Insert the starter supply connectors (3, 4) on the starter plugs (2) as shown in the figure. Fix the starter supply cables with the plastic cable clamp (1) as shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 109: Wiring Disassembly
Cut the cable tie joining the RJ-45 cable to the ECU signal cable. RJ-45 cable ECU signal cable Remove the 90° plug of the RJ-45 cable from the display by pressing the connector lever and pulling. Moster 185 EFI - Maintenance manual - V1/2024...
Page 110 Extract the RJ-45 cable from the elastic band of the display support. Unscrew the RJ-45 ferrule from the ECU socket and remove the RJ-45 cable. Moster 185 EFI - Maintenance manual - V1/2024...
Page 111: Wiring Assembly
Insert the RJ-45 plug into the ECU socket, screw the ferrule and tighten by hand. Crimp the RJ-45 cable to the ECU signal cable to avoid stress at the root of the connector. RJ-45 cable ECU signal cable Moster 185 EFI - Maintenance manual - V1/2024...
Page 112 Insert the 90° RJ-45 plug cable on the elastic band of the display support. Elastic 90° RJ-45 band plug Ferrite ring inside the elastic band Insert the 90° plug of the RJ-45 cable on the display. Moster 185 EFI - Maintenance manual - V1/2024...
Page 113: Temperature Probes
Screw M6x10: 10 Nm Screws M3x25: 0.4 Nm EGT sensor: 7 Nm Values *Always replace it when disassembled. 3.7.1 CHT sensor disassembly Extract the 2 screws M3x25 (1) from the sensors support. Moster 185 EFI - Maintenance manual - V1/2024...
Page 114 Extract the upper rubber stopper (2) from the sensors support. Extract the 2 rubber blocks (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 115 Remove the spark plug (see chapter 3.2.1 Spark plug disassembly). Remove the 2 self-locking nuts M4 (7), the M5 F8 cable clamp (8), the 2 external washers (9) and the 2 external rubbers (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 116 The carbon layer is flexible and will not be damaged during disassembly bending. Remove the cooling shroud (11) by bending it to make it pass over the 2 M5x30 studs (15). Moster 185 EFI - Maintenance manual - V1/2024...
Page 117 Extract the Allen screw M6x10 (16) and remove the CHT sensor (4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 118: Cht Sensor Assembly
Place the cooling shroud (11) on the airbox side as shown in the figure. Assembly requires bending the cooling shroud (11), so gloves must be used and force applied. The carbon layer is flexible and will not be damaged during assembly bending. Moster 185 EFI - Maintenance manual - V1/2024...
Page 119 Insert the spark plug (see chapter 3.2.3 Spark plug assembly). Insert the 2 external rubbers (14), the 2 external washers (13) and the 2 self-locking nuts M4 (12) and tighten by hand. Moster 185 EFI - Maintenance manual - V1/2024...
Page 120 M5 F8 cable clamp (8) in the position shown in the figure and the 2 self-locking nuts M4 (7) and tighten by hand. Pass the CHT cable (4) inside the sensors support hole. Moster 185 EFI - Maintenance manual - V1/2024...
Page 121 Insert the cables inside the rubber blocks (3) following the scheme shown in the figure. Insert the rubber blocks (3) inside their seats in the sensors support as shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 122 Insert the rubber stopper (2). Insert the 2 screws M3x25 (1) with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 0.4 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 123: Egt Sensor Disassembly
3.7.3 EGT sensor disassembly Extract the 2 screws M3x25 (1) from the sensors support. Extract the upper rubber stopper (2) from the sensors support. Moster 185 EFI - Maintenance manual - V1/2024...
Page 124 Extract the 2 rubber blocks (3). Disconnect the EGT sensor connector (5) from the power supply cable (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 125: Egt Sensor Assembly
Unscrew the EGT sensor (5). 3.7.4 EGT sensor assembly Insert the EGT sensor (5) with Interflon paste HT1200 on the EGT sensor thread and tighten with the torque shown in the figure. 7 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 126 Insert the cables inside the rubber blocks (3) following the scheme shown in the figure. Insert the rubber blocks (3) inside their seats in the sensors support as shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 127 Insert the rubber stopper (2). Insert the 2 screws M3x25 (1) with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 0.4 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 128: Air Rotary Valve
Check the air signal value shown on the display in the “Air signal value” screen of the info menu: The value should be stable over the entire lever movement range, otherwise replace the RJ-45 cable and repeat this check, if the problem persists replace the air rotary valve. Moster 185 EFI - Maintenance manual - V1/2024...
Page 129 Remove the bowden cable and check the bowden cable and the 2 nipples: if there are sings of wear, replace them. Remove the throttle swivel and check the throttle swivel hole on the lever: if it shows signs of wear, replace the throttle swivel. Moster 185 EFI - Maintenance manual - V1/2024...
Page 130 Remove the air rotary valve lever only if it needs to be replaced, otherwise proceed with the next operation. Remove the screw M4X8 (1), the lever (2) the 2 IGUS bushings (3) and the return spring (4). Remove the air rotary valve signal cable (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 131 Remove the 2 Allen screws M6x60 (6), the airbox connector (7) and the O-ring (8). Remove the air rotary valve (9) and the gasket (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 132: Air Rotary Valve Assembly
Place the airbox connector (7), with the O-rign (8). Insert the 2 Allen screws M6x60 (6) with threadlocker (recommended Loxeal 55-03/Loctite 243) in the airbox connector (7), screw progressively, then tighten with the torque shown in the figure. 6 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 133 2.5 Nm Insert the fuel injector (see chapter 3.4.4 Fuel injector assembly), the bowden air rotary valve cable, plug the start/stop button cable and insert the airbox (see chapter 3.3 Airbox), Moster 185 EFI - Maintenance manual - V1/2024...
Page 134: Reed Valve
Remove the 4 Allen screws M5x25 (1) from the air rotary valve flange (2). Remove the following components from the crankcase (7): air rotary valve flange (2), gasket (3), flow guide with O-ring (4), reed valve (5), gasket (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 135 Remove the 2 screws (8) from one side of the reed valve (5). Remove the stoppers (9) and petals (10). Carry out the same operations on the other side of the reed valve. Moster 185 EFI - Maintenance manual - V1/2024...
Page 136: Reed Valve Maintenance
(left side of the photo). In the right side of the photo, you can see a deformed petal that remain slightly raised. If the previous checks are not passed or if routine maintenance is required, replace the petals. Moster 185 EFI - Maintenance manual - V1/2024...
Page 137: Reed Valve Assembly
M3x5 (8) and tighten with the torque shown in the figure. 1.5 Nm Check that the petals rest perfectly on the surface of the reed valve (see previous photos). Carry out the same operations on the other side of the reed valve. Moster 185 EFI - Maintenance manual - V1/2024...
Page 138 Insert the 4 Allen screws M5x25 (1) into the air rotary valve flange (2), tighten progressively, then with the torque shown in the figure. 8 Nm Insert the air rotary valve (see chapter 3.8 Air rotary valve) and the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 139: Battery
3.10.1 Electric starter 60A fuse disassembly Make sure the battery is turned off and disconnected from the charger and from the engine. Remove the 4 screws M2X10 (1) from the upper battery cover. Moster 185 EFI - Maintenance manual - V1/2024...
Page 140 Remove the upper battery cover (2). Remove the 2 self-locking nuts M5 (3). Remove the 60A fuse (4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 141: Electric Starter 60A Fuse Assembly
Make sure the battery is turned off and disconnected from the charger and the engine. Place the electric starter 60A fuse (4) on the 2 screws M5x12 (5). Insert the 2 self-locking nuts M5 (3) and tighten with the torque shown in the figure. 5 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 142 Place the upper battery cover (2). Insert the 4 screws M2x10 (1) and carefully tighten by hand. Moster 185 EFI - Maintenance manual - V1/2024...
Page 143: Gaskets
Also, if the motor is not used for a long period of time, check the condition of the gaskets. For gasket replacement see the following chapters: 3.8 Air rotary valve, 3.9 Reed valve, 3.12 Exhaust system and 3.17 Piston, cylinder, head. Moster 185 EFI - Maintenance manual - V1/2024...
Page 144: Exhaust System
Silencer nuts: 10 Nm Screw M8x25: 14 Nm. Values *Always replace it when disassembled. 3.12.1 Manifold, exhaust bushings disassembly Before proceeding with the next operations, remove the EGT sensor (see chapter 3.7.3 EGT sensor disassembly). Moster 185 EFI - Maintenance manual - V1/2024...
Page 145 Remove the 4 bushing springs and the 3 exhaust manifold springs. Remove the exhaust manifold (1), the 2 self-locking nuts M8 (2) with the washers (3), the exhaust flange with bushing (4) and the gasket (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 146 Remove the bronze ring (6) from the exhaust flange (4). Remove the bronze ring (7) from the exhaust manifold (1) by pushing from the two notches in the exhaust manifold (1). Moster 185 EFI - Maintenance manual - V1/2024...
Page 147: Manifold, Exhaust Bushings Maintenance147
For routine maintenance, follow the table. Check that the exhaust joints are regular. Small defects on the surface (sticking marks, cracks, steps) must not prevent a regular motion of the joint. Moster 185 EFI - Maintenance manual - V1/2024...
Page 148 Clean the end of the exhaust manifold (8), sand it with sandpaper and apply Molykote grease. Clean the second joint (9) with an abrasive sponge (e.g. Scotch-Brite), degrease it with solvent and apply Molykote grease. Moster 185 EFI - Maintenance manual - V1/2024...
Page 149: Manifold, Exhaust Bushings Assembly
Press the bronze ring (7) on the exhaust manifold (1). Check that the bronze ring (7) comes into contact with the seat of the exhaust manifold (1) to prevent leakage from the exhaust system. Moster 185 EFI - Maintenance manual - V1/2024...
Page 150 Add copper paste to the nuts. Insert the 2 self-locking nuts M8 (2) with the washers (3) and tighten with the torque shown in the figure. Position the exhaust manifold (1). 32 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 151 Run one cable around the 4 bush springs, insert a clamp at each end and tighten with pliers. Apply heat shrinkable hoses. Insert the EGT sensor (see chapter 3.7.4 EGT sensor assembly). Moster 185 EFI - Maintenance manual - V1/2024...
Page 152: Silencer Disassembly
Remove the Allen screw M8x25 (1), the 2 washers (2) and the rubber (3) from the silencer support. Remove the 3 self-locking nuts M6 (4) and the 3 nuts M6 (5) from the upper end of the silencer (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 153 Before disassembling the silencer mark the position of the end caps with an erasable marker Drill the 8 rivets centrally using a drill with a 5 mm diameter bit. Position reference mark Moster 185 EFI - Maintenance manual - V1/2024...
Page 154 Use a heat gun to heat the end caps (8, 11) in order to facilitate the release of the silicone. Remove the following components from the silencer housing (10): the end caps (8, 11) and the sound-absorbing material (9). Moster 185 EFI - Maintenance manual - V1/2024...
Page 155: Silencer Maintenance
Check the integrity of the silencer body both internally and externally: there must be no cracks or damaged areas, otherwise replace it. For routine maintenance, follow the table. Check the integrity of the silencer band, otherwise replace it. Moster 185 EFI - Maintenance manual - V1/2024...
Page 156: Silencer Assembly
Fix the end caps on the body with 8 rivets respecting the references taken during disassembly. Make sure that the end caps are fully inserted before fixing. Wet the rivets with high-temperature silicone (Loctite 5900) before fastening and fix the end caps (8, 11) on the body. Moster 185 EFI - Maintenance manual - V1/2024...
Page 157 Insert the 3 nuts M6 (5) on the silencer then the 3 self-locking nuts M6 (4). Tighten the with the torque shown in the figure. Tighten the first 3 nuts progressively to guarantee a correct alignment of the silencer. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 158 Insert the rubber (3), the 2 washers (2) and the Allen screw M8x25 (1) with threadlocker (recommended Loxeal 83-55/Loctite 270) and tighten with the torque shown in the figure. 13 Nm Insert the EGT sensor (see chapter 3.7.4 EGT sensor assembly). Moster 185 EFI - Maintenance manual - V1/2024...
Page 159: Rubber Mountings
3.13.1 Rubber mountings disassembly Before proceeding with the next operations, remove the EGT sensor (see chapter 3.7.3 EGT sensor disassembly). When locking the rubber mountings during maintenance take care not to damage them. Moster 185 EFI - Maintenance manual - V1/2024...
Page 160 Remove the safety cable around the springs. Remove the 4 bushing springs (1). Remove the 3 self-locking nuts M8 (2) with washers (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 161 Remove the exhaust system (4). Remove 3 self-locking nuts M8 (5) and 3 rubber mountings of the exhaust system (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 162 Remove the FIU (see chapter 3.5.1 FIU disassembly). Remove the 4 ring nuts DIN 981 - KM4 (7). Remove the 2 steel brackets (8). Moster 185 EFI - Maintenance manual - V1/2024...
Page 163 Remove the 4 FIU spacers (9). Remove the 2 engine rubber mountings (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 164 Remove the 2 remaining engine rubber mountings (11) and the 2 self-locking nuts M6 (12). Remove the 4 screws M4x10 (13) and the 4 FIU rubber mountings (14). Moster 185 EFI - Maintenance manual - V1/2024...
Page 165: Rubber Mountings Maintenance
3.13.3 Rubber mountings assembly Place the 4 FIU rubber mountings (14) and insert the 4 screws M4x10 (13) with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 1.6 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 166 (6). Replace the 2 self-locking nuts M8 (12). Insert the 2 self-locking nuts M6 (12), the 2 engine rubber mountings (11) and tighten with the torque shown in the figure. 18 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 167 Insert the 4 spacers (9) with threadlocker (recommended Loxeal 55-03/Loctite 243). Bring them into contact with the engine rubber mountings (10) and then tighten 45° making sure to block the rotation of the engine rubber mountings (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 168 Place the 2 steel brackets (8). Insert the 4 ring nuts DIN 981 - KM4 (7) and tighten with the torque shown in the figure. 20 Nm Insert the FIU (see chapter 3.5.3 FIU assembly). Moster 185 EFI - Maintenance manual - V1/2024...
Page 169 Insert the rubber mounting of the exhaust system (5) shown in the figure (rubber 14/20 soft M151a), the self-locking nut M8 (6) and tighten with the torque shown in the figure. 15 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 170 Replace the 3 self-locking nuts M8 (2). Insert the 2 self-locking nuts M8 (2) with washers (3) on the rubber mountings shown in the figure and tighten with the torque shown in the figure. 18 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 171 Run a cable around the 4 bushing springs, insert a clamp on the ends and tighten with pliers. (see chapter 3.12.3 for spring assembling operations) Insert the EGT sensor (see chapter 3.7.4 EGT sensor assembly). Moster 185 EFI - Maintenance manual - V1/2024...
Page 172: Electric Starter
Screws M6x25: 10 Nm. Screws M6x10: 10 Nm. Values *Always replace it when disassembled. 3.14.1 Electric starter disassembly Disconnect the battery. Before disassembling the electric starter, remove the belt (see chapter 3.16 Transmission). Moster 185 EFI - Maintenance manual - V1/2024...
Page 173 Remove the 2 flange head screws M6x25 (1) from the electric starter plate (2). Remove the O-ring (3) from the starter plate. Cut the plastic clamp (5). Moster 185 EFI - Maintenance manual - V1/2024...
Page 174 Remove the supply cables (6, 7). Remove the 2 Allen screws M6x25 (8) with washers (9) from the electric starter (4). Remove the electric starter (4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 175: Electric Starter Maintenance
Insert the 2 Allen screws M6x25 (8) with washers (9) into the electric starter (4) and tighten with the torque shown in the figure. 10 Nm Plug the supply cables (6, 7) as shown in the figure. Moster 185 EFI - Maintenance manual - V1/2024...
Page 176 Position the reinforcement plate (2). Insert the 2 flange-head screws M6x25 (1) in the plate (2) and tighten with the torque shown in the figure. 10 Nm Insert the belt (see chapter 3.16 Transmission). Moster 185 EFI - Maintenance manual - V1/2024...
Page 177: Flywheel, Coil
Before disassembling the flywheel, remove the spark plug (see chapter 3.2 Spark plug) and the FIU (see chapter 3.5 Full integrated unit (FIU)). Screw the piston lock into the spark plug hole. Moster 185 EFI - Maintenance manual - V1/2024...
Page 178 Remove the 4 Allen screws M6x14 (1) and the ring gear cover (2). Remove the nut M10x1,25 (3) with the washer 10,5x18 (4). Do not use a pneumatic impact screwdriver, otherwise the piston may be damaged. Moster 185 EFI - Maintenance manual - V1/2024...
Page 179 Screw the flywheel extractor into the flywheel (5). Turn the central pin of the extractor until the flywheel (5) is removed from the crankshaft. Moster 185 EFI - Maintenance manual - V1/2024...
Page 180 Remove the self-locking nut M4 (6) and the M5 F8 cable clamp (7). Remove the M4x20 screw (8), the self-locking nut M4 (9) and the M5 F8 cable clamp (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 181 Remove the M4x12 screw (11) and the M5 F6 cable clamp (12). Remove the coil signal cable (13) Moster 185 EFI - Maintenance manual - V1/2024...
Page 182 Remove the 2 Allen screws M5x20 (14) with washers (15). Remove the ignition coil (16). Moster 185 EFI - Maintenance manual - V1/2024...
Page 183 Remove the 3 Allen screws M5x20 (17) and the toothed pulley (18) from the flywheel (19). Moster 185 EFI - Maintenance manual - V1/2024...
Page 184: Flywheel, Coil Maintenance
Measure the resistance of the coil: if out of tolerance replace it. COIL POSITION RESISTANCE IGNITION COIL HV.CABLE-EARTH 4,8 kOhm +/- 10%, (@25°C) IGNITION COIL FASTON-EARTH CONTINUITY OR CLOSE TO 1 OHM Moster 185 EFI - Maintenance manual - V1/2024...
Page 185: Flywheel, Coil Assembly
Insert the ring gear (21) on the toothed pulley (18), the 4 screws M4x16 (20) and tighten with the torque shown in the figure. Insert the 4 nuts M4 (22). Replace the 4 screws M4x16 (20) each time the ring gear is disassembled 4,1 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 186 Replace nut M10x1,25 (3) and washer 10,5x18 (4). Insert the nut M10x1,25 (3) with the washer 10,5x18 (4) and tighten with the torque shown in the figure. 52 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 187 Place the ignition coil (16). Insert the 2 Allen screws M5x20 (6) with washers (7) without tightening. Moster 185 EFI - Maintenance manual - V1/2024...
Page 188 Place 0,3 mm shims between the ignition coil and the flywheel. Tighten the ignition coil screws by hand. Remove the shims. Insert the coil signal cable (13). Moster 185 EFI - Maintenance manual - V1/2024...
Page 189 Fix the spark plug cable (24) with the M4x20 screw (8), the self-locking nut M4 (9) and the M5 F8 cable clamp (10) in the position shown in the figure and tighten by hand. Moster 185 EFI - Maintenance manual - V1/2024...
Page 190 Insert the toothed pulley (18) on the flywheel (19), the 3 Allen screws M5x20 (17) with threadlocker (recommended Loxeal 55-03/Loctite 243) and tighten with the torque shown in the figure. 8 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 191 Insert the 4 Allen screws M6x14 (1) and the ring gear cover (2) and tighten with the torque shown in the figure. 10 Nm Insert the FIU (see chapter 3.5 Full integrated unit (FIU)) and the spark plug (see chapter 3.2 Spark plug) Moster 185 EFI - Maintenance manual - V1/2024...
Page 192: Transmission
*Always replace it when disassembled. Before proceeding with the next operations on the transmission, remove the airbox (see chapter 3.3 Airbox). 3.16.1 Belt removal Remove the hexagonal screw M8x16 with washer from the pulley eccentric. Moster 185 EFI - Maintenance manual - V1/2024...
Page 193 Remove the Allen screw M6x35 on the eccentric side. Turn the eccentric clockwise to release the belt tension. Remove the belt from the pulley. Moster 185 EFI - Maintenance manual - V1/2024...
Page 194: Belt Disassembly
3.16.2 Belt disassembly Remove the pulley and washer. Remove Seeger ring (1) from the seat on the pulley (2). Moster 185 EFI - Maintenance manual - V1/2024...
Page 195 Remove the eccentric (3) with the 2 bearings from the pulley (2). Remove the 2 Seeger rings (1, 4), the 2 bearings (5) with a bearing extractor and the spacer (6) from the eccentric (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 196: Bell, Clutch Disassembly
Remove the cover (7) from the clutch bell (9): for removal, insert a self-tapping screw M4x35 in the centre of the cover (7). Remove the Seeger ring (8). Use an extractor with a maximum hook length of 4 mm. Moster 185 EFI - Maintenance manual - V1/2024...
Page 197 Position the extractor (10) on the clutch bell (9). Turn the central pin (11) until the clutch bell (9) is removed. Moster 185 EFI - Maintenance manual - V1/2024...
Page 198 Turn the crankshaft anti-clockwise until the piston is in contact with the piston lock. Heat the clutch to facilitate disassembly. Unscrew the clutch (13) until it is removed from the crankshaft (14). Do not use a pneumatic impact screwdriver, otherwise the piston may be damaged. Moster 185 EFI - Maintenance manual - V1/2024...
Page 199 Heat the clutch bell to 120 °C. Remove the Seeger ring (15) and the 2 bearings (16, 17) from the clutch bell (9). Moster 185 EFI - Maintenance manual - V1/2024...
Page 200: Transmission Maintenance
Check that the belt does not show signs of wear or damage (as in photo), otherwise it must be replaced. If the belt has not been used for a long time, check that it is soft, otherwise it must be replaced. For routine maintenance, follow the table. Moster 185 EFI - Maintenance manual - V1/2024...
Page 201 Check the axial play of the clutch pads, it must not exceed 1 mm, otherwise the clutch will damage the clutch bell. 1 mm 1 mm The photo shows a damaged clutch bell due to excessive axial play in the clutch pads. Moster 185 EFI - Maintenance manual - V1/2024...
Page 202 Factory settings at 20° C (mm) 41,970-41,980 34,980-34,990 34,980-34,990 89,45-89,55 Measure the diameter of the bearing seat on the eccentric, the table shows the factory settings. Dimension Factory settings at 20° C (mm) 20,005-20,015 Moster 185 EFI - Maintenance manual - V1/2024...
Page 203: Bell, Clutch Assembly
Insert bearing 6202-C-2HRS (16) into the clutch bell in the position shown in the figure. Insert the Seeger ring (15). Insert bearing 6202-C-2Z (17) into the clutch bell in the positions shown in the figure. Wait for the clutch bell to cool down. Moster 185 EFI - Maintenance manual - V1/2024...
Page 204 Heat both inner rings of the bearings (16, 17 of the previous image) simultaneously up to 80 °C. Pay the utmost attention when heating the rear bearing (16) because it has a rubber shield. Place the clutch bell (9) and the Seeger ring (8) on the shaft. Moster 185 EFI - Maintenance manual - V1/2024...
Page 205 Insert the cover (7) into the clutch bell (9). Check that the cover (7) is positioned on the clutch bell (9) as shown in the figure: the cover (7) must not be in contact with the shaft (14). Moster 185 EFI - Maintenance manual - V1/2024...
Page 206: Pulley Assembly
Pay the utmost attention when heating the bearings (5) because they have a rubber shield. Place the bearings (5), spacer (6), bearing (5) and Seeger ring (4) on the eccentric (3). Position the Seeger ring (1) on the eccentric (3). Moster 185 EFI - Maintenance manual - V1/2024...
Page 207 Heat the central part of the pulley to 120 °C. Insert the eccentric (3) with the 2 bearings in the pulley (2). Position the Seeger ring (1) in the seat inside the pulley (2). Moster 185 EFI - Maintenance manual - V1/2024...
Page 208 Replace the washer (18) with the same thickness as the ones replaced. Possible sizes range from 0 mm (no washer) to 0,6 mm. Insert eccentric with pulley and washer (18). Moster 185 EFI - Maintenance manual - V1/2024...
Page 209: Belt Insertion
3.16.7 Belt insertion Turn the eccentric to position it as in the figure. This position facilitates the insertion of the belt. Place the belt on the pulley and clutch bell. Moster 185 EFI - Maintenance manual - V1/2024...
Page 210 Insert the hexagonal screw M8x16 with washer into the eccentric of the pulley. Insert the Allen screw M6x35 on the side of the eccentric. Moster 185 EFI - Maintenance manual - V1/2024...
Page 211: Belt Tensioning
Replace the Allen screw M6x35 every 3 belt retightenings. Only replace with original Vittorazi components. Tighten the Allen screw M6x35 to 12 Nm. Manually turn the pulley a few turns. Check the belt tension again, retighten if necessary. Insert the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 212: Piston, Cylinder, Head
(see chapter 3.12 Exhaust system). Remove the 4 self-locking nuts M8 (1) with washers (2) from the engine head (3). Remove the head (3), the O-ring (4), the cylinder (5) and the gasket (6). Moster 185 EFI - Maintenance manual - V1/2024...
Page 213 Remove the circle clip (8), the pin (9), the piston (10) and the roller bearing (11). Remove the 2 piston rings (12) and the circle clip (13) from the piston (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 214: Piston, Cylinder, Head Maintenance
Check the selection class engraved on the piston. Measure the diameter of the piston at 16 mm from the base of the shell. Measure the diameter of the cylinder 10 mm from the top. Moster 185 EFI - Maintenance manual - V1/2024...
Page 215 Determine the maximum clearance, if equal to or greater than the indicated value replace the piston and/or cylinder. Check the piston and cylinder for signs of seizure, otherwise replace them. For routine maintenance, follow the table. Moster 185 EFI - Maintenance manual - V1/2024...
Page 216: Piston, Cylinder, Head Assembly
Oil the following components with the oil used for the mixture: the roller bearing (10), the pin (8), the piston rings (11) and the piston (9). Insert the 2 piston rings (11) into the piston grooves (9), paying attention to the position of the 2 piston ring retainers. Moster 185 EFI - Maintenance manual - V1/2024...
Page 217 Insert the circle clip (13) on the piston (10) respecting the position shown in the photo. The triangle on the top of the piston indicates the exhaust side. Insert the roller bearing (11), the piston (10), the pin (9) and the circle clip (8). Moster 185 EFI - Maintenance manual - V1/2024...
Page 218 Check the squish measurement on the pin axis: acceptable values range from 1,35 mm to 1,55 mm. If the squish is out of tolerance, increase or decrease the thickness of the cylinder base gasket until the required result is obtained. Moster 185 EFI - Maintenance manual - V1/2024...
Page 219 Insert the exhaust system (see chapter 3.12 Exhaust system), the CHT sensor (see chapter 3.7.2 CHT sensor assembly), the spark plug (see chapter 3.2 Spark plug) and the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 220: Crankcase
(see chapter 3.14 Electric starter), the FIU (see chapter 3.5 Full integrated unit (FIU)), the flywheel, the coils (see chapter 3.15 Flywheel, coil), the transmission (see chapter 3.16 Transmission) and the cylinder unit (see chapter 3.17 Piston, cylinder, head). Moster 185 EFI - Maintenance manual - V1/2024...
Page 221 Remove the 4 countersunk head screws M8x16 (1) and the crankcase support (2). Remove the 5 Allen screws M6x35 (3) and 2 Allen screws M6x40 (4). Moster 185 EFI - Maintenance manual - V1/2024...
Page 222 Position the extractor (5) on the crankshaft (6), tighten the 4 screws M8 (7) and turn the central pin (8) until the 2 case-half are separated. Moster 185 EFI - Maintenance manual - V1/2024...
Page 223 Remove the oil seal (9) from the crankcase support (2) on the side shown in the figure. Heat the FIU side crankcase to 120 °C. Remove the bearing (10). Moster 185 EFI - Maintenance manual - V1/2024...
Page 224 Remove the crankshaft (6) using a press in the direction shown in the figure. Heat the transmission side crankcase to 120 °C. Remove the bearing (11) and the oil seal (12). Moster 185 EFI - Maintenance manual - V1/2024...
Page 225: Crankcase Maintenance
Check the 2 bearing seats: there must be no polished areas. Also measure the diameter of the 2 seats, the table shows the factory settings. Dimension Factory settings at 20° C (mm) 46,960-46,980 46,960-46,980 Moster 185 EFI - Maintenance manual - V1/2024...
Page 226 Measure the clearance at the small end and big end of the connecting rod. Factory nominal clearance* (mm) Small end 0,008-0,017 Big end 0,022-0,031 * at 20 °C Check on the connecting rod that there are no areas of different color due to overheating. Moster 185 EFI - Maintenance manual - V1/2024...
Page 227 Measure the eccentricity of the crankshaft, the factory settings are shown in the figure. Check that the seat of the key is undamaged. If the above checks are not passed, replace the crankshaft. Moster 185 EFI - Maintenance manual - V1/2024...
Page 228: Crankcase Assembly
Heat the inner rings of the 2 bearings (10, 11) and fit it on the crankshaft (6). Heat the transmission side crankcase to 120 °C. Insert the crankshaft (6) with the bearings. Moster 185 EFI - Maintenance manual - V1/2024...
Page 229 Carry out subsequent operations within a maximum of 5 minutes (application of silicone and closing of the crankcase). Carefully add silicone paste (Three Bond 1215) to the crankcase profile as shown in the figure. Height, width silicone profile: 2 mm x 2,5 mm. Moster 185 EFI - Maintenance manual - V1/2024...
Page 230 Close with the FIU side crankcase still warm at 120 °C. Insert the 5 Allen screws M6x35 (3), the 2 Allen screws M6x40 (4) and tighten with the torque shown in the figure. 10 Nm Moster 185 EFI - Maintenance manual - V1/2024...
Page 231 (between the plane of the reed valve and the cylinder base plane). Wait for the crankcase to cool down. Check the tightening of screws. Insert oil into the 2 lubrication holes (highlighted in the figure). Check the sliding of crankshaft on the bearings. Moster 185 EFI - Maintenance manual - V1/2024...
Page 232 Replace the oil seal (9) each time it is disassembled. Grease the oil seal (9) with FP Silicompound 225 and place it on the crankcase support (2) using the specific tool (13) to insert it. Moster 185 EFI - Maintenance manual - V1/2024...
Page 233 Carefully add silicone paste (Three Bond 1215) to the crankcase profile as shown in the figure. Height, width silicone profile: 2 mm x 2,5 mm. Moster 185 EFI - Maintenance manual - V1/2024...
Page 234 Insert the 4 countersunk screws M8x16 (1) on the crankcase support (2) and then cross-tighten with the torque shown in the figure. 20 Nm Check that the hole shown in the figure is not blocked by silicone. Moster 185 EFI - Maintenance manual - V1/2024...
Page 235 (see chapter 3.9 Reed valve), the CHT sensor (see chapter 3.7.2 CHT sensor assembly), the air rotary valve (see chapter 3.8 Air rotary valve) and the airbox (see chapter 3.3 Airbox). Moster 185 EFI - Maintenance manual - V1/2024...
Page 236: Tightening Values
0,6 Nm Loctite 243 clamp screw Probes support 3 Nm fixing plate nuts ECU signal cable Loxeal 55-03/ M6x10 fixing clamp 10 Nm Loctite 243 screw The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 237 Reed valve petals M3x5 1,5 Nm screws Battery self- 5 Nm locking nuts Copper paste Exhaust nuts 32 Nm Silencer nuts 10 Nm The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 238 M4x20 screw Aluminium Loxeal 55-03/ toothed pulley’s 8 Nm M5x20 Loctite 243 screws Ring gear cover 10 Nm M6x14 screws 20 Nm Clutch The table follows in the next page Moster 185 EFI - Maintenance manual - V1/2024...
Page 239 M8x16 screw Eccentric side 12 Nm M6x35 screw Cylinder head 16 Nm Copper paste nuts Engine carter 10 Nm M6x35/40 screws Carter support 20 Nm M8x16 screws Carbon propeller 10-12 Nm screws Moster 185 EFI - Maintenance manual - V1/2024...
Page 240 Moster 185 EFI - Maintenance manual - V1/2024...
Page 241 Moster 185 EFI - Maintenance manual - V1/2024...
Page 242 Moster 185 EFI - Maintenance manual - V1/2024...

Vittorazi Motors MOSTER 185 EFI Maintenance Manual

1 Introduction

2 Be Careful! Read It Completely

3 Maintenance

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