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Post by keltex78 on Feb 19, 2014 15:07:23 GMT -5
- I did not re-grease the new rollers when I installed them. I was told that the Dr. Pulley products are intended to be used dry. Even so, I'm at the point where I think I'll just grease them anyway to reduce the clatter.
- On my return trip, I did not have the CVT cover installed, so it's not on that component; it would be on the CVT housing. I do see what looks like a place where the belt has rubbed against the housing, but have no idea why it suddenly started doing so after 4k+ miles, and immediately after I rebuilt the Variator? I'm planning setup a camera pointed at each of the pulleys this evening, crank the bike with the cover removed, then rev the engine up to normal running RPM while recording video, so I can see exactly what the belt is doing at that speed.
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Post by keltex78 on Feb 19, 2014 10:53:50 GMT -5
Further adventures with the CVT on my 244cc Jonway @ ~4400 miles: In an attempt to quiet a noisy variator, I removed and cleaned the variator, and replaced the factory rollers with a set of Dr. Pulley rollers, same weight and micrometer verified same size. I had also purchased a spare belt. While I had the CVT apart, I replaced the belt as the factory Gates-branded belt was stretched out a bit as compared to the new. Assembled all, and I still got the same clatter from the rollers, but the bike ran perfectly, so I drove it to work yesterday. On my way back home, with less than 50 miles on the new belt and rollers, at highway speed, I immediately lost all torque and coasted to a stop on the side of the road. The motor was still running and revved fine, so I pulled the CVT cover off and this is what I had left of my belt:  Stranded on the side of the road, I called a friend who came and drove me home, where I got my original Gates belt and brought back to the scooter. I installed the belt, cranked the bike, and drove the ~10 miles back home. On arriving, I checked the belt and found this deep gash beginning to develop in the previously-undamaged belt:  I'm not quite sure what is causing this gash as there are no foreign obstructions that match up with this. My only idea now is that the variator pully is pulling the belt too far to the outside causing the belt to abrade against the inside of the housing? This only happened after I serviced the variator; there were absolutely no issues before! What am I missing here? |
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Post by keltex78 on Feb 14, 2014 14:59:20 GMT -5
Hmmmm... okay... and that would also explain why my rollers don't seem that secure. When I completely assemble the variator, then shake it upside down, rollers can be dislodged from their ramps. I mentioned that in my other thread and no one seemed concerned...
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Post by keltex78 on Feb 14, 2014 14:41:11 GMT -5
Alleyoop, Yes, my variator had an extremely thick and sticky grease from the factory. It appeared to have mostly been slung to the outside edge of the variator where it harderend in place, and none was left on the ramps. When I replaced my rollers, I thouroughly cleaned the variator and installed the new Dr. Pulley rollers. Per directions received here, I did NOT relube the variator and new rollers. I purchased new rollers that were 23*18, the same as the factory rollers, and the same as recommended for my bike. Should I have purchased 24*18 rollers? I'm beginning to think my next step would be to purchase a new variator, but a Dr. Pulley is $170!  |
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Post by keltex78 on Feb 14, 2014 11:08:09 GMT -5
Jonway YY250T, 244cc Honda clone:
I've recently been chasing down some unsual clatter from the variator side of my CVT. In an attempt to troubleshoot the issue, I removed the variator, then cranked the bike and noted that the clatter had stopped. I then reinstalled the variator with a new belt and new Dr. Pulley rollers, but on cranking the bike, I noted that the clatter had returned. Is tihs a normal clatter for a CVT/Variator or is this something more serious? At this time, the bike runs great, no hesitation or bogging. The clatter is constant up until ~30mph when it smooths out.
The change in volume at the halfway point was my moving the microphone away from the bike slightly...
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Post by keltex78 on Feb 12, 2014 16:00:53 GMT -5
No rust yet... But I've only had it for a few months, and it generally gets driven for long runs, so plenty of time to cook any moisture out of the muffler...
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Post by keltex78 on Feb 11, 2014 18:02:03 GMT -5
"If the women don't find you handsome..."
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Post by keltex78 on Feb 11, 2014 17:58:24 GMT -5
RoadRunner delivery here. The driver had a 50' trailer and couldn't negotiate the roads in my neighborhood so we made arrangement to meet in a parking lot. He said he couldn't take the scooter back once I opened the crate. (How else am I supposed to inspect it for damage before accepting, especially when the crate is already damaged?) I opened it anyway, then we pushed the bike while still mounted to the crate directly from his lift into the bed of my pickup. Uncrated while in the truck and rolled it off. Welds on the crate had broken, but bike was mostly undamaged. After having accepted the shipment, I found a cracked panel underneath, but it's hidden and not a problem.
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Post by keltex78 on Feb 3, 2014 16:47:51 GMT -5
Update @ ~4500 miles: As per my last update, the factory tires were pretty well gone at 3500 miles. I replaced those with a pair of Shinkos and I have to say the process went really well! itistheride.boards.net/thread/4916/tire-change-resourcesI installed the new tires (along with bolt-through right-angle valve stems) using the zip-tie method and it worked great! I was able to break the bead using my $15 (Sale+coupon) Harbor Freight bead breaker then brute-force removed the tire from the rims using tools I already had. That was the hardest part of the job. I used the jumbo Harbor Freight zip ties and a spray bottle of soapy water to mount the new tires, which went on easily. So far, I've put about 1000 miles on the Shinkos and they've been great! It has a much smoother ride, and my chicken strips are much smaller now... Next, I've replaced nearly every bulb on the scooter with LED replacements that are all much brighter while using much less power. I'm hoping to create a new thread in the near future with info on the bulbs I'm using. I have a burned out low-beam element on one of my headlights, so I'm replacing those. I noticed that the headlight reflector assembly is keyed for H4-style bulbs, so I've ordered a pair of 45W H4 bulbs and the H4 plugs to splice into the wiring harness. Better quality bulbs, with an extra 10W/each should mean a good bit of extra light without too much heat on the reflector. I'm hoping. I'll post here with my success story if it all works out well. Finally, @ ~4300 miles, I completed my first valve adjustment; nothing to it on these 244cc motors. When I received the bike, I was disappointed that I didn't get the 257CC Linhai model I had ordered, but after a single valve adjustment, I'm glad to have this one... I recently noticed several large cracks appearing around the mount holes on the bottom of my trunk. I intended to repair the trunk with fiberglass resin but ultimately purchased a replacement trunk from eBay. I purchaesd this trunk: www.ebay.com/itm/310788231341...for $35 shipped and like it a lot. It's made out of a better quality plastic and doesn't rattle like the old trunk did. It's smaller and won't carry quite as much, but is deeper, so it will hold my full-face helmet. The locking mechanism feels much better, and the trunk retention system feels very secure. I like having the option to remove the trunk, but I'm not sure if I'll ever really use that feature. I'm surprised at the difference in quality between the factory trunk and the cheapest aftermarket trunk I could find! The factory trunk is junk compared to this one... I've also developed a noisy rattle in the CVT. I took the variator apart and didn't like the way it looked so I've ordered new roller weights and will be putting it back together once they come in. I ordered a set of Dr. Pulley replacement roller weights in 26g. which matches the factory weights I removed. I also purchase a new drive belt since I already have the unit fully pulled apart, even though I still have a lot of life left on the factory Gates Powerlink belt. I'll keep that as a spare to have on hand. Full story on the CVT saga here:http://itistheride.boards.net/thread/5251/noisy-cvt At about 4000 miles, I pulled and replaced the spark plug with a new iridium NGK, but was surprised to find that the factory plug was also a NGK (non-iridium). Color looked good, didn't look like it was running rich, or too lean. Also, the mounting bracket for the air filter had shattered into pieces! I ended up purchasing a new filter (~$10) and installing that.... |
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Post by keltex78 on Feb 3, 2014 14:49:08 GMT -5
I just ordered a set of replacement Dr. Pulley rollers (not sliders, just being moderately cheap here) along with a replacement drive belt from partsforscooters.com. (Edit: Wow! Just over an hour from time I ordered and already shipped with a tracking number!) I went with 26g weights, same as the factory since I was happy with performance already. I'll be putting it all back together once I get the parts...
The variator had a lot of a VERY thick/sticky/nasty grease all around the outside rim; the grease was caked on and very difficult to clean off. With the new Dr Pulley rollers, should I use a dry lube (graphite or other) or would a more conventional grease be better. I have both graphite powder and white lithium grease available already...
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Post by keltex78 on Feb 3, 2014 11:33:15 GMT -5
Here are the pictures of the variator: First, This is what I found on removing the cover:  As I mentioned, one of the screws holding the variator cover broke off on removal. After cleaning, I saw what appears to be adhesive around the broken screw. I'm assuming that the factory worker assembling this unit stripped the threads so he just glued the screw in place. Now I'm going to have to drill it out and re-tap the hole. It's not grease; it's definitely a hardened substance:  These are the rollers after cleaning:  Just one more question: With the variator completely assembled with the rollers in place, if it is shaken or turned over, the rollers fall out of their tracks. This doesn't seem right to me. Does the variator rely on the belt to hold pressure against the rollers or is this a more severe issue? |
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Post by keltex78 on Feb 1, 2014 22:29:47 GMT -5
Okay, measuring my rollers;
18mm x 23mm x 26g.
Bike is a highway commuter; I weigh about 180lbs. Typically run @~60-65 mph, just shy of WOT. Slider or roller, should I bump up the weight to get me a bit easier top end?
Going to go ahead and get a replacement belt while it's torn down; factory belt is a Gates Powerlink and still has a lot of life left, so I'll keep that as a spare.
Edit:
All of my factory rollers have a heavy dark glazing over the white material; is that normal?
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Post by keltex78 on Feb 1, 2014 15:17:07 GMT -5
Okay, I've cleaned the factory rollers to examine them more closely and they appear to be in pretty bad shape. Several flats on all them, and one in particular that is worn more on one end than the other... Time to order...
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Post by keltex78 on Feb 1, 2014 14:05:08 GMT -5
So, @ 4300 miles, rollers that are already border-line too small begin to wear which pushes then below the limit resulting their jumping out of track?
The rollers do show wear so in any case, I plan to replace them, most likely with sliders...
Edit...
Just weighed my rollers, 26g, verified by individual weights and then all together divided by six. So would I match weights to go to sliders or should they be changed?
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Post by keltex78 on Feb 1, 2014 13:37:27 GMT -5
Jonway YY250T, 244CC:
This week, my scooter began making a loud clattering noise while at idle the noise seemed to die out over ~30mph. This afternoon, I removed the CVT cover to determine if the sound was from belt flop or something else. Without the cover, I noted the same sound coming from the actual CVT pully, so I removed that from the bike. With the pully assembly removed, I recranked the bike and noted that the rattling had been eliminated.
I then placed the CVT pully face down, and removed the three screw holding the roller assembly cover plate in place, breaking one of the screws in the process. On removing inner roller retaining plate (?) I noted that three of the rollers were not correctly seated in their channels. I do not see any damage to the rollers or CVT but the condition I found it in seemed unusual to me, along with the sudden onset of the noise. I have a picture of the assembly as I found it when opened but it will be Monday before I can post that.
So, is this cause for alarm?
Should I clean and reassemble the CVT I have?
Should I replace this unit with a new one?
Or should I use this as an opportunity to upgrade from rollers to sliders? :-)
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