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Post by flatland2d on Jul 26, 2014 20:41:47 GMT -5
Yesterday I went to recheck my valve clearances and tune the idle air mix screw since I haven't touched that since I installed the new carb. Intake was set at 0.004", exhaust at 0.005". I set the exhaust back down to 0.004" where I last put it. Also adjusted the idle air mix screw. I only mention this because the next problem I had came after I put everything back together, but I don't think these would be related. After finishing that job, I started getting a weird vibration around 20 mph and up. It was kind of an on-off-on-off cycle about once or twice a second. Didn't seem to happen during deceleration. I also noticed a weird sound, presumably coming from the engine, that sounded like a ch-ch-ch-ch sound after coming to a stop, then it would go away. That may have something to do with me tweaking the idle air mix screw (I set it around two turns out). Anyway, some reading about the vibration issue pointed to the belt flapping around in the CVT. I decided to take the CVY cover off to see if there was anything odd inside. Upon taking the cover off, these metal pieces fell out. They were around the rear pulley area. The scooter has around 800 miles on it so the belt should be broken in. I decided to stop working for the night so I never got to see where these metal pieces came from. Can anyone tell me where these go? What part do I need to replace? Also, the CVT cover gasket broke upon removal. Is that pretty normal? I was hoping to reuse it, but after seeing it tear, I don't think I can.  |
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Post by alleyoop on Jul 26, 2014 20:51:55 GMT -5
Hard to tell but you may want to check out the Clutch Pad arms, some are known to break. Or it could be parts of the inside of the CVT casing itself If you have a kickstarter.
Picture of the CVT with the cover off would probably tell if its part of the casing itself.
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Post by geh3333 on Jul 26, 2014 20:57:19 GMT -5
Yesterday I went to recheck my valve clearances and tune the idle air mix screw since I haven't touched that since I installed the new carb. Intake was set at 0.004", exhaust at 0.005". I set the exhaust back down to 0.004" where I last put it. Also adjusted the idle air mix screw. I only mention this because the next problem I had came after I put everything back together, but I don't think these would be related. After finishing that job, I started getting a weird vibration around 20 mph and up. It was kind of an on-off-on-off cycle about once or twice a second. Didn't seem to happen during deceleration. I also noticed a weird sound, presumably coming from the engine, that sounded like a ch-ch-ch-ch sound after coming to a stop, then it would go away. That may have something to do with me tweaking the idle air mix screw (I set it around two turns out). Anyway, some reading about the vibration issue pointed to the belt flapping around in the CVT. I decided to take the CVY cover off to see if there was anything odd inside. Upon taking the cover off, these metal pieces fell out. They were around the rear pulley area. The scooter has around 800 miles on it so the belt should be broken in. I decided to stop working for the night so I never got to see where these metal pieces came from. Can anyone tell me where these go? What part do I need to replace? Also, the CVT cover gasket broke upon removal. Is that pretty normal? I was hoping to reuse it, but after seeing it tear, I don't think I can. Anyone notice the " T " on the smaller broken peice . Maybe someone can identify where it came from . |
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Post by flatland2d on Jul 26, 2014 20:58:29 GMT -5
Thanks alleyoop. I may try to get a pic of the inside tomorrow, but from everything I could see, nothing looked broken on the cover or inside the CVT. Since these were back near the rear pulley, some on the back side being covered up by the pulley, I couldn't see everything inside.
For reference, the largest piece is roughly the size of a nickel and they all seem slightly curved.
I should note though, that even though it looks like something catastrophically failed, the scooter ran fine except for that little vibration, and before I messed with it yesterday, it was perfect.
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Post by rockynv on Jul 27, 2014 5:28:20 GMT -5
Looks like the covers on the weights inside the clutch. You will need to remove the clutch bell to check them out. Do not ride the bike with them like this or you chance destructive vibrations that can destroy frame components, the muffler, do head damage where the muffler flange attaches and ruin the input shaft bearings on the gearbox. Pay attention to the condition of the shaft the clutch rides on to ensure it is not scored or roughed up and be sure to apply grease to the roller bearings inside the center of the clutch before putting it back on after inspection it if there is nothing wrong with it. If you replace it still be sure to clean off the shaft and apply grease to the needle bearings inside the center of the clutch.
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Post by flatland2d on Jul 27, 2014 14:24:13 GMT -5
rockynv, I think you are correct. Two of the three clutch shoes show damage. This is the good one:  This is one of the bad ones:  Most of the replacement parts I'm finding on ebay are the entire clutch, so I guess that's what I will be replacing. Any sense in getting a "racing" or "performance" clutch, or one with a different RPM spring? I'm planning on selling this in a few months when I go to upgrade so I don't need anything too great, I just ride it around town. Lastly, I'm having some trouble getting the variator off, even with a pneumatic impact driver and the variator held down so it can't move. Any tips to get this off with the impact driver? If not, I'll have to rig up something else so I can use a 1/2" breaker bar.
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Post by phssthpok on Jul 27, 2014 16:18:43 GMT -5
Most of the replacement parts I'm finding on ebay are the entire clutch, so I guess that's what I will be replacing. Any sense in getting a "racing" or "performance" clutch, or one with a different RPM spring? I'm planning on selling this in a few months when I go to upgrade so I don't need anything too great, I just ride it around town. Any particular reason you want/need to remove the variator? If you're just looking to remove the belt it can be done without removing the variator. |
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Post by alleyoop on Jul 27, 2014 16:51:37 GMT -5
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Post by geh3333 on Jul 27, 2014 19:36:13 GMT -5
How does the clutch bell look inside ? From the pic the pads look like there are lines or groves in them " yes they could have been damaged from the broken pieces " . They just look strange .
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Post by alleyoop on Jul 27, 2014 20:43:47 GMT -5
Those pad arms where not poured as one piece they are made of pieces of metal and sandwiched together those are the lines your seeing. Actually those are much stronger than the forged ones. But is not what broke off what partly broke off is the piece where the clutch material is glued to.
Alleyoop
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Post by flatland2d on Jul 27, 2014 23:55:51 GMT -5
I tried the no-tools method to remove the belt, but it turns out I was doing it wrong so it didn't work. I'll try it again when the new clutch comes in. Mostly I just wanted to inspect the variator because I haven't taken it apart yet in the time I've owned the scooter. I might be interested in replacing the rollers, but I don't know what I have stock. I really don't want to lose any top end.
Inside the clutch bell looks perfectly fine. No damage, very smooth.
The new clutch should be here in a couple of days. Looking forward to being good as new again!
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Post by rockynv on Jul 27, 2014 23:56:08 GMT -5
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Post by geh3333 on Jul 28, 2014 17:10:07 GMT -5
Those pad arms where not poured as one piece they are made of pieces of metal and sandwiched together those are the lines your seeing. Actually those are much stronger than the forged ones. But is not what broke off what partly broke off is the piece where the clutch material is glued to. Alleyoop Yeah I had a stock clutch that looked like that , but mine didn't have the outer shell over the " sandwiched arms" . I never noticed the lines in the pads though . But I only used that clutch for a few miles then I installed the ncy clutch . I actually sent the stock clutch assembly to someone on the site a couple yrs ago for free . They needed a clutch and since I had a few extra I thought I'd just give him one . |
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Post by Kwagga on Jul 29, 2014 1:31:17 GMT -5
Google 'Variator Removal Tool', and then select 'Images' and you will see pictures of them. Very easy to make or have made.
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Post by flatland2d on Jul 29, 2014 20:13:56 GMT -5
I made my own variator removal tool and it started the crack the variator where the pegs go into the holes on the variator to lock it up. Might need a new variator because of that. I'm planning on doing the rope in the cylinder method next.
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..BAD TO THE BONE..
