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Post by scooterpookin on Aug 19, 2014 0:36:31 GMT -5
First of all I just want to say that I love my scoot. It's one of those things where you don't appreciate something until it's gone. So here's what I got; Riding back from work and I hear the scoot start dying on me. Then I hear something come loose internally like the transmission is free spinning and then it bogs out on me and I'm unable to restart. Noticed when trying to start the scooter the starter spins much faster then usual and won't catch. Investigation; Decided to pop her open and...  its covered in a thick layer of black dust. I removed the kick-start assembly because it broke a while back and the opening for the kick has been open for some time. I also found some chunks of the old belt when it broke off. Would the opening cause this much dirt? Seems like oil to me. Took off the pulleys, belt and cleaned up a little.   And this fell out  seems important a spacer maybe? I have a feeling it came from the Driver pulley. Noticed some shavings on the post coming out of the engine.  and found some grinding on the corresponding pulley...  That was my uneducated question. Guilty Note; This is my intense procrastination. So I've been having problems with the Trans Drain Bolt i cant seem to get it off with all my might. And I cant fit an impact wrench underneath without laying the scooter over. I don't know when the transmission fluid has been changed, not since I've had it. Conclusion; I feel like the grinding along with the broken spacer could result in the free spinning. Too much friction from lack of lubricant and dirt causing it to grind out...maybe? But I don't know why it won't start. Could be connected. Video: |
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Post by geh3333 on Aug 19, 2014 1:43:30 GMT -5
The spacer is from the kick start shaft , you must have left it in without knowing , the teeth on the drive face look very bad Do not use it ! have you ever tried to add any gear oil ? It seems as if the teeth on the crank look pretty good still " at least in the pic" . How are the plastic v slides on the back of the variator , there should be 3 of them . You have a problem somewhere in the cvt and we need to find it . Your gonna have to check the gear box at this point " bearings etc." so U will have to get that drain plug out . Do u have a pipe or a breaker bar ? That bolt should come out . Your turning it upside down so be sure to turn it the right way . Also these gear boxes tend to leak somtimes " very slow leaks" hopefully it's not dry .
If the gear box has been dry for a while then the bearings are probably bad which will cause the engine to work harder and run hotter , hopefully the internals are ok but one step at a time . First you will need to drain the gear box . I guess if u cannot get the drain plug out just get a container big enough to catch the gears oil " if any" as u remove the cover . Let us know what u find . If you are able to get the plug off and it's not dry let us know . The main thing we need to figure out is why the teeth " splines " are ground off , and if the gear box is dry .
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Post by pmatulew on Aug 19, 2014 5:25:31 GMT -5
The debris on the floor looks like rubber dust from the belt. Seems like a lot, but not extraordinary. It may be a little oily if the crankshaft seal is leaking. I concur that the broken spacer bushing looks like it came from the kick start assembly. Not sure why that was still floating around in there without a home. May be it was hiding in the hole inside the cover and got missed.
The partially stripped spline teeth inside the drive face are definitely where the metal shavings came from. That part will need to be replaced. If the remainder of the teeth fit the crankshaft splines properly, then I can only suppose that the drive face wasn't properly seated and torqued down against the variator bushing. On my 150 when re-installing the drive face I have to snug it down part way and then rotate the engine and snug it down again a couple times so the belt has a chance to settle evenly and the drive face seats correctly.
The transmission drain you'll just have to keep abusing until you get it loose. In the meantime old oil is less bad than no oil. Squirt some in the top hole until it starts to run out. Or make yourself a dipstick out of a piece of wire or a pipe cleaner to verify that there is at least something in there besides air.
The engine not starting is a separate issue. Those functions are all "inside the box" and not related to the transmission. It may be related to "intense procrastination" and lack of maintenance though. You'll need to start at the top and work your way down the normal list. Air? Gas? Spark? Compression? Valve clearance adjust?
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Post by geh3333 on Aug 19, 2014 9:34:33 GMT -5
Maybe someone put the washer on befor the drive face ? , that may cause the teeth to be ground off and have a tiny bit left . Not sure though .
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Post by alleyoop on Aug 19, 2014 14:14:56 GMT -5
Did you guys also notice the belt, looks lit it is the wrong size I mean it actually flops on top. Yes that scoot needs a little TLC that cvt looks like it hasn't been taken care of at all. The not starting is a complete different issue from the problems in the cvt. PMATULEW you are right on  Alleyoop |
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Post by geh3333 on Aug 19, 2014 16:45:43 GMT -5
I think the problem with the belt is that is wore down " very bad ". In the first pick , is that part of the belt in the bottom left ? If so it looks horrible . Also is he still using that drive face ? The belt is probably the right size but in horrible condition . Also his starting issue is obviously a separate problem but was probably caused by not taking care of the cvt and possibly the gear box .
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Post by scooterpookin on Aug 19, 2014 21:12:46 GMT -5
Thanks for the posts. I'm gonna take a look at the gear box and I'll post pics. Any more info on taking it apart? Drain plug; I'm not going anywhere with it so I might as well take the time to prop the scoot over so I can get an impact wrench in there and pop it loose. It shouldn't be completely dry cause I did squirt some gear oil In to it before. But I'll find out for sure. The belt in the vid is loose because I just put the pulleys on to see if they would spin and hear the engine so they definitely weren't tight. The belt looks fine to me...  geh3333 in the first pic bottom left that's my size 10 1/2  |
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Post by scooterpookin on Aug 21, 2014 0:34:07 GMT -5
I'm having the hardest time on the Gearbox. I cant seem to get it off. I've taking off all the bolts in this picture I can see where the separation is but even with all the bolts, rear tire, and brake cable removed it still doesn't budge. Am i missing something? I didn't realize how easy it was to remove the engine. I might just pull the whole thing out for ease/coolness |
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Post by geh3333 on Aug 21, 2014 1:15:29 GMT -5
You still have 5 bolts to remove . That is to remove the gearbox cover . There are two bolts above the clutch shaft and one below . And there are two bolts all the way to the right at the edge of the case . Also can you measure the width of the belt and let us know what it is " in mm" that will tell you if the belt needs replaced . It also looks as if you may have a bolt to the lower left of the shaft also . Did you try to remove the plug below ?
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Post by geh3333 on Aug 21, 2014 1:23:27 GMT -5
Lol that's funny , your boot blended into the floor and I thought the edge of your boot was the belt lol . Just to let you know I've been using an iPhone 4 to get on here and I have to look at pics and watch vids on this massive screen . Lol
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Post by scooterpookin on Aug 21, 2014 16:23:01 GMT -5
Geh3333 sorry that's was an old picture I've removed every bolt on the cvt including the drain bolt. I think maybe the seal is what keeping it stuck together.
There was gear oil in it, it was dirty but it was definitely not empty.
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Post by geh3333 on Aug 21, 2014 20:16:47 GMT -5
Are the teeth on the variator shaft ok ? If so did you order a new drive face ? Also if you can take some pics of the clutch , pads , and springs that would be helpful . If you can also measure the width of the belt . Do you have a pic of the cvt before you tore it apart ? I'd like to see if the variator nut looked to be loose or not or if anything looked out of place .
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Post by scooterpookin on Aug 25, 2014 16:01:40 GMT -5
Got a whole new variator assembly in the mail today (it was 4 more dollars then just the fan) finally got the gearbox off with a little tapping of a hammer. Everything seems fine to me plenty of oil and the gear teeth look good. I don't have a picture before I TOOK it apart, haha but I did have to use an impact wrench to remove the bolt. I'm gonna put the new assembly on and then I'll check back in.    |
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Post by scooterpookin on Aug 25, 2014 22:20:23 GMT -5
Ok got the new variator assembly on nice and shiny everything slides on properly.  But I noticed something, I think y'all were right about the belt. Its not in bad shape, i think its just the wrong size. I can make the two sides touch each other.  I was still able to scoot like this, so i didn't mess with it, but after a long period of time the bouncing around could have ground out my drive face. Here's the belt code:835 20 and 2507 SC 095-098  I also realize I haven't told you what my scoot is: 150cc GY6  also what of the Short case long case? maybe i stoopid and have been using the long case belt.... |
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Post by scooterpookin on Aug 26, 2014 16:53:39 GMT -5
Ok so im still trying to figure this one out. I think I have a short case. But just in case here's a little more specs. When i measure my cvt case its right at about 18 1/2 in from tip to tip  And my tire is a 130/60-13  What do you think short case? if so then I should have a 743 20 30?? thanks |
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..BAD TO THE BONE..