finally had to work on it

[dademoss]

Well i finally had to work on the Scooter after 3600 miles of trouble free service .
it was nothing major, my wife and I went on a yellow ribbon ride for SSG. Matt Maupin Scholarship Fund
After a while of running with the Big Boys on their harleys and 2 up the variator started to hang and the rollers would not return i decided
to tear it open and check it out to see what was up
and besides a variator full of grease nothing was found so im not really sure what happened
So i just went ahead and cleaned it up in there
I started out pulling the metal floor plates
and side valance




Then off with the CVT air intake


and then the CVT Cover its self


and then with my trusty 12V electric Impact wrench and 19mm socket took off the nut (no tool needed to hold the variator)
slide the front half of the pulley off then the belt and finally the back half of the pulley with all the weights and crap in it

[dademoss]

Now after getting the variator off i opened it up and WOW it had a heck of a lot of grease in there



i got my kerosene and brake cleaner and cleaned and scrubbed and cleaned some more.
Now following the yamaha service manual each weight got a fine coat of grease on each side oh and i did mic the weights at 20mm book out of spec if they are 19.5 also they had just the tiniest flat spot on them which i thought was pretty good.
Now just put her back together


Now while i had it apart and did not really find anything wrong besides a butt load of grease i figured why not
I loved how Kliffs 150 CVT cover looked so i opened my 250s up (hoping it may have been a heat problem causing my trouble)


Painted and deglazed the clutch bell


Painted the scratched up valances (both sides of scooter)


and put it all back together


and blew the rear valve stem apart on the rear wheel whilst spinning it up to check for noise and such but thats a different fix

[Rebel]

Good job. Thanks for posting it.

[dademoss]

Hey JR didnt you do a mix roller set the stock mixed with 12s to give a 13.5 ?

[xs650]

Jul 14, 2009 14:51:24 GMT -5 dademoss said:

and blew the rear valve stem apart on the rear wheel whilst spinning it up to check for noise and such but thats a different fix

You couldn't have picked a more convenient time or location for that one.

[dademoss]

ok Just an FYI for everybody !
After the variator Issue i thought i had it resolved but i was wrong
i took the scooter out for a little run and it seemed ok so i parked it for the night got it out the next morning fired right up warmed it up for a bit and off i went well at about 4000 rpm it hit a wall started to sputter and hesitate its get up and go got up and went ,so back to the house i went low end is fine mid range wall hit if you could get up to 5000 rpm it was ok again.
Now from what i can figure these variators are really kinda picky when it comes to the amount of grease that is in them seems like the more the better.
Now i followed the YP250 bookas it pertains to the 257cc Linhai engine the BOOK says a light coat of grease on each side of each weight in the variator i did that but that amount of grease DID NOT allow for the weights move freely enough and a few of them had started to hang and not move right .
during throttle roll on a few weights would like get stuck , it was not a carb problem, valve adjustment or plug none of the above
i pulled the CVT back apart pulled the variator got some good molybdenum with graphite recleaned the weights and greased the horse poo out of the ramps top and bottom all the little valleys and the weights themselves put it back together again and it is now A1 again hesitation is gone no sputters nothing just get up and GO again

[Rebel]

sounds strange to me, seems like a bunch of extra grease would kind of get int the way of those rollers, rolling freely. But if it works it works.

[dademoss]

i did notice that when i hit some of the grease with the brake cleaner it just kinda balled up like giraffe poo but smaller it never dissolved or even got thin now most of it did but some of it no
now it did have a slight odor but nothing like the poo suckin truck