cvt cover removal and kick start By rgmarsing (Read 2,356 times)

[rgmarsing]

[/img] Part of my 2000 mile maintenance was to inspect my cvt. I probably should have looked at it soon after I got my scoot but since it ran great I neglected to do so. I also thought it was about time to find out what size drive belt was on it in case I needed to get a new one.
I read many of the threads on inspection, repair and upgrades so I thought I wouldn't have any problems. Wrong!!
Bolts were easy enough to take out (I even drew a simply diagram of cover on a piece of cardboard and placed each bolt in a hole punch in the drawing where it was located because some bolts are different length according to some videos I watched. Mine were all exactly the same). I then tried to remove the cover and no way was it coming off. I had a rubber mallet as suggested to give some light persuasion also and still nothing. I then used a flat scewdriver to gently tap around the seam and stated to get some movement but still it would not come off. I finally had to do some prying, which I was reluctant to do because of damage to the gasket but finally got it off. Gasket not in to good of shape. Some still stuck ti the motor some on the cover.
Now good news. Other than some black dust (expected) the insides look real good. The belt looked brand new still. I was a little surprised at the size (906 22.5) but later found this was a common size for scoots with 16" wheels, which is what I have.
So I now want to take off the variator to check on the rollers and see what weights they are. I had stopped at the hardware store earlier to pick up a 17 mm socket which almost all the threads and sites I've read say is probably the one, but its not. It's a 3/4". I didn't have an impact socket of that size so that will have to wait.
Since this is my only transportation I decided to clean everything up and put it back together. Since the gasket wasn't in very good shape (salvaged what i could) I used some permatex on the cover and tried to put it back on. Wow. Nothing wanted to line back up. The cover was warped. I had to put in some bolts part way and use my rubber persuader to get some more alignment and slowly work more bolts along with gentle taps and some more tightening and some more taps and some more tightening until I finally got them all in and tightened.
Has this happened to anyone else? It sure looked much easier in all the videos. If it's going to be this hard to do I don't think I'll do much experimenting in variators and roller weights. And what about the Permatex. will that cause a Problem?

[jct842]

As far as I am concerned I could care less about sealing up the case. I do not use a gasket and besides that I drilled a host of 1/2 inch holes around the clutch so the belt and clutch could breath cooler air. If you look at the case the inlet is bigger than the outlet. Besides that I live on a dirt road and still do not have a problem with dirt build up. All I can say about using permatex is you are going to have fun to get it apart when the time comes again/

[Bashan]

I run one of my 150s without a cover and nothing has gone wrong with the CVT. Lose the gasket, it's a PITA. Some guys put a thin teflon or rubber washer on each bolt and run with the gap to provide some ventilation. As John said, the intake opening scoops dust in anyway, the gap won't matter. If you do use the gasket put some Permatex dressing on it so it will come off.

[rgmarsing]

Thanks Bashan and jt. Still wondering about the warped cover though. Is that common? The small wahers would probably make it a little easier to take off and put back on, but its so far off alinement it would still be a problem.

[sprocket]

There have been discussions about metal CVT covers providing ridigity to the rear of the transmission...sounds reasonable, but I don't know if it is true

[rgmarsing]

I took the cover back off again today because I must have accidently messed up the alignment of the gears on my kickstart. It was much easyier to take off this time and also to get back on. Still not easy, easyier. I thought I got the gears lined up properly but I guess not. I can't try the kickstart with out the cover on so off it comes again. I moved everything around on the gears so they looked like they would work when I tried them by hand but when I got the cover back on again (not too bad this time. Either its loosening up or just tired of me beating on it with a hammer. Or maybe I'm just getting better at it.) It still wont work.
Are there any pictures or vids on kickstarts I can look at? Since I like to take my Cadillac scoot (see my pics on pics and video forum) out on some long multi night rides into the mountains I really want the kickstart to back up my battery

[Bashan]

Also, you might want to read this thread over.

[rgmarsing]

Thanks Bashan. The photo looks a lot like mine and the arrow 150 manual post by sprocket on the link above is very informative. I'll give it another go and let you know. Hey it rhymes. lol

RG