Please follow the instructions carefully, and use all tools listed
below, if you are in any doubt with fitting the kit in any way please
NoteThe Varitronic has variable timing and also sparks much more efficiently then any current electronic
system on the market, because of this you will need to re jet your carburettor to suit.
Timing Light (Strobe Gun)
Timing disc or dial
32mm Ring spanner
10, 17 and 19mm
Fitting the Stator
When fitting the stator plate initially affix the base plate in the centre of its adjustment. Feed the wire out through the top wiring plates, and secure the stator in place, make sure the wires are secured properly with the wiring tag and they do not rub the flywheel. Using a new woodruff key, temporarily fit the
flywheel and then find TDC on your scooter; the most accurate way is to use the positive stop method.
Once you have TDC, opposite the arrow on the flywheel, make a small mark with a marker pen or similar.
With a dial gauge, timing disc, or other accurate method you then need to measure out your desired timing (refer to instructions below for final timing settings).
Wiring The System In
Follow the instructions as provided on the sticker that comes in your kit, which briefly is as follows :-
Wiring depends on the wiring loom you use, the choices are original, replacement or electronic loom.
1) Electronic loom :- following the diagram sticker, the green from the wiring loom connects to terminal one from the CDI. The brown from the wiring loom should be joined with the yellow/white from the stator, and connected to terminal 3 on the regulator. All other connections are as per the diagram included with the kit.
2) Original or replacement looms :- Non Battery machines. The original green wire going to the coil will have a ring terminal on it. Cut this and replace it with one of the spade terminals provided in the kit. This wire goes to terminal one on the CDI. The other end of the green that was in the junction box, needs to be either left on its own in the junction box touching nothing or connected to nothing else, or taped up. The brown, purple and pink wires from the main wiring loom need to be connected together. The best way to do this is to use an electronic junction box, or a bolt and fit ring terminals to each wire, then then "screw" them together. Make an extension wire from either the junction box, or the joined wires and run this to the regulator. The extension wire needs to be joined to the white/yellow from the stator and is then plugged into terminal 3 on the regulator. The rest of the wires from the stator should be connected as per the diagram. Fit 12v bulbs.
3) Original or replacement looms : Battery Machines. For original style battery machines where you want to retain the use of the battery for parking lights, horn and brake light should be as follows. The original green wire going to the coil will have a ring terminal on it. Cut this and replace it with one of the spade terminals provided in the kit. This wire goes to terminal one on the CDI. The other end of the green that was in the junction box, needs to be either left on its own in the junction box touching or connected to nothing else, or taped up. The brown and purple wires from the main wiring loom need to be connected together and are then joined by the yellow/white wire from the stator and are connected to terminal 3. The grey and red wire from the main wiring loom also need to be connected together, and they go to terminal B on the regulator. Do not forget you need to fit a 12V battery, bulbs and horn!
In all instances careful attention to the earths are needed, the Varitronic requires all earths to be correct and present!
On the Varitronic loom from the stator, the blue connects to the regulator, and then links to the coil as shown in the wiring diagram. The important part of this earth is that this must also go to the scooter frame, and then back to engine casing to complete the earth. We suggest fixing on the frame leg, and then a cowling securing bolt, both of which are where the original earth es would have been. Make sure the rear light is earthed properly to the frame, the headset earths are correct and secure.
Fitting the flywheel
Using a new woodruff key fit the flywheel onto the crankshaft, please note the flywheel requires a 32mm ring spanner as a holding
device to lock it while you tighten the flywheel on. Torque the flywheel to
50lbs anti clockwise using a torque wrench, this is vitally important, damage will occur if you do not use a torque wrnech to the correct setting!
Setting the timing
At fast idle, set the timing to either 21 degrees if using a standard / big bore / Ancillotti type exhaust, or 19 degrees if using any expansion chamber. To do this you need to start the scooter up (checking the flywheel nut is secure) and test where the timing is with your strobe gun. If you need to adjust the timing, take the flywheel off and rotate the stator plate. Rotating the plate anti clockwise will retard the timing, while the opposite clockwise will advance it.
Notes on timing
Due to the nature of the Varitronic and the way it works, it can be tuned to your individual Lambrettas set up to achieve differing results. As with jetting a carburettor, adjusting your timing affects how and where your scooter makes power, handles heat build up, how efficiently it burns the fuel/oil/air mix e.t.c. Ideally you would set any timing system to the maximum advance you could possibly use without the scooter destructing by means of heat build up.