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Let’s
start with the variator:
1. Remove the kick starter from
the CVT side cover.
2. Remove all the bolts with an 8mm socket that hold the CVT cover.
3. Remove the CVT cover, trying not to break the gasket; if you damage
the gasket, I suggest you order a new one.
4. You have now exposed the front pulley (Variator) as well as the rear
pulley (Clutch) with the belt connecting the two.
5. I always recommend installing a new belt, once you have the cover
off, and are going to perform the upgrades.
6. Using an impact wrench (preferably), remove the nut holding the
variator. Once you have removed the nut, remove the variator fan
(outside part of the variator).
7. You can now slide the belt off the shaft (crank) and remove it from
the clutch pulley as well.
8. Remove the variator by sliding it off the shaft, be carefull, as you
need to reach behind the variator and hold on to the pressure plate as
well, in order to prevent the rollers from dropping out.
9. Install the new roller weights into the new variator, making sure
they are properly seated in their slots.
10. Slide the new backing plate onto the variator, making sure that the
plastic sliders are also properly installed on the backing plate.
11. Holding the new variator securely with the backing plate, and the
new rollers installed, slide it back on to the shaft. (do not install
the new variator fan at this time)
Let’s move on to the clutch
now:
1. Using the impact wrench remove the nut, holding the clutch &
pulley.
2. Slide the clutch bell off the shaft.
3. This will expose the clutch & pulley assembly.
4. Slide the assembly off the shaft.
5. We are now going to install the new clutch and the new main (torque)
spring.
6. If you do not have a professional clutch stand, follow my
instructions, but be aware the main spring is under load, so be careful.
7. Place the clutch on a solid floor, with the clutch side facing up.
8. If you do not have help, place both you feet on either side of the
clutch, placing pressure downward on the clutch, holding it in position.
9. Use your impact driver to remove the large nut holding the clutch, do
this very slowly, as you remove the nut, then slowly release the
pressure with your feet, and the spring will unload slowly, and clutch
will come away, releasing the large spring.
10. Install the new spring & clutch, and reverse the process,
compressing the spring with the clutch. (it is much easier if you have
somebody help you with this part)
11. As you compress the clutch, be very careful not to cross thread the
large nut, make the first few rounds by hand, and only then use the
impact wrench to tighten the nut back on.
12. Slide the assembly back on to the shaft, install the clutch bell
back on the shaft, be sure to line up the splines, and then tighten the
nut back on the shaft.
Now we install the belt:
1. Place the belt over the clutch pulley.
2. Take both your hands (you will need somebody to help you here) and
pull back on the clutch to open it slightly, let your assistant now push
the belt slightly into the clutch pulley as you open it up. This allows
the belt to reach over the front shaft. You only have to insert the belt
a small way in.
3. Now pull the belt over the front shaft.
4. Now install the variator fan, be sure to line up the splines on the
fan with the shaft, hand tighten the nut as far as it will go. Gently
using the impact wrench, tighten the nut.
5. Install the CVT cover, with the new gasket, tighten all the bolts, on
some scooters there may be a ground wire that you must not forget to
bolt up as well.
6. Install the kick start lever.
Congratulations, you have just upgraded your
CVT!
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