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Post by JonwayRider on Apr 28, 2011 0:22:49 GMT -5
Hey guys, long time reader here.
I have a Jonway 150cc.
I changed the belt on it probably at about 2000km. Everything seemed fine for the next 1800 or so km when I noticed it was REALLY sluggish on takeoff, like it was in its 'final gear' so to speak. It did this for about a day until last night I was running an errand to the store when I could feel it ever-so-slightly jerk, almost unnoticeable. And then all of a sudden the engine just quit. I pushed it maybe a quarter of a mile or so to the nearest location to where I could call someone to pick it up. I tried to start it today and it will start over with half to full throttle but as soon as I let off the throttle it will quit. I took the CVT cover off and it looks like the clutch is not disengaging, as in the belt is riding to the bottom or middle of where it should be. Think I need a new clutch?
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Post by edfr on Apr 28, 2011 0:51:33 GMT -5
Could be your Variator weights are stuck in the open position and not allowing the variator to retract to drop the belt in the Variator and it is just pulling on your clutch so the belt would be down in the Clutch pulley.
Lefty
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Post by JonwayRider on Apr 28, 2011 1:10:38 GMT -5
If it helps, there is some slack in the bottom of the belt but at the top its as tight as can be. And the belt is showing some wear on the inner side (The side closest to the engine.
EDIT: Also I noticed when it first started, if I gave it gas, it seemed like it would pop back into the idle position. Before it quit, it would not 'pop back'.
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Post by edfr on Apr 28, 2011 1:14:23 GMT -5
Can you tell where it is hanging up by the Variator or the Clutch Pulley, if there is slack only on one side something is OUT OF LINE. Look down from behind the scoot and see which pulley is tilted IN on the top or tilted out on the bottom.
Lefty
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Post by JonwayRider on Apr 28, 2011 1:22:48 GMT -5
Wow, I didnt realize the variator actually moved besides the rotating factor. I guess that why I came here to learn more. Lefty, I cant really tell right now as its dark outside but I'll try and get some pics, possibly a video up so you guys can diagnose it for me.
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Post by edfr on Apr 28, 2011 1:26:33 GMT -5
Cool! maybe the Variator NUT came loose and the OUTSIDE Pulley is wobbleing and got stuck.
Tommorrow see if you can grab it and rock it in and out. Hope that is all that happened.
But take it all off and check your weights just in case they got out of position.
Lefty
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Post by JonwayRider on Apr 28, 2011 1:37:23 GMT -5
Lefty, I'm pretty new to taking this thing apart so I wouldnt know if the weights were in the wrong position or right. Plus I dont have tools to take the variator off. From what I've read, you need some sort of an impact wrech to get it off.
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Post by edfr on Apr 28, 2011 1:58:55 GMT -5
BUMMER!! You have to get some tools, otherwise it will cost you more money paying someone to fix most things on your scoot. Mechanics charge money just to check it out then hit you with parts and labor. And some are not the sharpest knifes in the drawer either, they may know how to replace parts until the problem goes away. So if you get some tools we will teach you how to fix your own scoot they are really not hard to fix and well save you a lot of money in the long run. The hardest is diagnoseing which part or what is causing the problem. To get the Variator off you at least need a socket set with big enough sockets for the Variator Nut and Clutch Nut. You can probably get away without an Impact wrench but they do make it a hell of a lot easier to take off the nuts and put them back on. You can get an Electric Impact 110V which is what I use and works like a champ. You can google for them to find the cheapes one you can find Harbor Freight has good ones and for a good price. Lefty Something like this: www.harborfreight.com/hand-tools/sockets-accessories/52-piece-socket-set-35338.htmlwww.harborfreight.com/1-2-half-inch-electric-impact-wrench-45252.html |
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Post by JonwayRider on Apr 28, 2011 3:16:17 GMT -5
I actually have a socket that will fit on the variator. Can I do this without having some sort of special tool?
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Post by Hammerspur on Apr 28, 2011 4:55:51 GMT -5
I actually have a socket that will fit on the variator. Can I do this without having some sort of special tool? Standing at center is the special hi-tech device I use to hold variator fan and/or clutch bell:    Use a cheater (pipe) on the handle if more leverage is needed to prevent turning while loosening or re-torquing nut with ratchet. OR, you could make one like this: www.nyscooterclub.com/forum/viewtopic.php?f=5&t=14593 |
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Post by JonwayRider on Apr 28, 2011 5:35:51 GMT -5
Pardon me for being a little slow, but what exactly does that wrench fit to in order for me to loosen the variator nut?
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Post by JonwayRider on Apr 28, 2011 6:10:11 GMT -5
Here is a picture from the back. Attachments:
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Post by JonwayRider on Apr 28, 2011 6:14:06 GMT -5
Heres one from the side....if you need a picture of the clutch, I have a couple of those. Attachments:
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Post by JonwayRider on Apr 28, 2011 8:58:42 GMT -5
Ok, so a friend of mine looked at it and he said the rollers look like theyre stuck. Were tried everything to get the variator off and the bolt will not budge. I cant afford an impact wrench or one of those locking tools. Any other way to get this thing off?
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Post by philr54 on Apr 28, 2011 9:32:08 GMT -5
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Post by JonwayRider on Apr 28, 2011 9:45:07 GMT -5
Yeah, I cant even afford to make anything. One of those poor college kids. Any other options?
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Post by Hammerspur on Apr 28, 2011 11:17:39 GMT -5
Pardon me for being a little slow, but what exactly does that wrench fit to in order for me to loosen the variator nut? The vanes on the variator fan in this case. Or the slots/holes in the clutch bell if you need to turn that nut off at some point. Yeah, I cant even afford to make anything. One of those poor college kids. Any other options? For $5.99 from Harbor Freight you might try one of these: www.harborfreight.com/20-inch-chain-wrench-97073.html Or for $7.99 one of these: www.harborfreight.com/locking-chain-clamp-36813.html Pad around the vanes of the fan with an old leather belt or something before clamping chain wrench on... should work, but be careful, you don't want to break one of those cast fins. Have both, used that 2nd tool last night to disassemble my clutch  |
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Post by edfr on Apr 28, 2011 14:51:01 GMT -5
Yea, that is what I thought the Variator is stuck holding the Belt up high and down on the Clutch. Well you have to get something to hold the Variator from turning and if the nut on there is that tight putting something in the FINS of the Fan will most likely break the fins. So you are going to have to spend a few bucks but not as much. Go to an auto parts store and get an OIL WRENCH, but make sure it is big enough to go onto the Variator Fan. So measure the width of the variator and get one that will fit. Then you can also use it when you have to take the Clutch off as well, works for both. Lefty www.autozone.com/autozone/accessories/Tools-Garage-and-Equipment/Oil-Filter-Wrench/_/N-25ra |
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Post by sprocket on Apr 28, 2011 15:22:32 GMT -5
I've used a large rubber strap wrench and it works OK. They are about $8.00 at Harbor Freight
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Post by Hammerspur on Apr 28, 2011 18:31:00 GMT -5
I've used a large rubber strap wrench and it works OK. They are about $8.00 at Harbor Freight Yeah, tried that too but No Way! Nut was much too tight. The monkey wrench jaws levered judiciously in the fins worked easily enough though. I plan to try the 1/2" square drive chain wrench over a pad to remount and torque the nut, 55 N-m / 40.56 ft. lbs. per factory service manual. Pretty certain it'll work fine. |
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Post by JonwayRider on Apr 29, 2011 16:08:40 GMT -5
Well, I had to break down and buy an oil filter wrench to take the variator off, and it worked with the help of a breaker bar. I took a look at the rollers and most of them were flat spotted. I took my old weights to a local scooter shop and they gave me new ones to put in. I got everything put back on, the nut is tightened down very hard. So hard in fact that I broke the end of an extention off. I start it up, everything seems normal until I get on to ride. It is so slow to take off. Did I not tighten down the variator enough?
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Post by sprocket on Apr 29, 2011 16:19:13 GMT -5
You need to torque the variator nut to 35-40 Nm. Sounds like the shop have given you the wrong weights...
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Post by edfr on Apr 29, 2011 16:20:56 GMT -5
That is what I was going to say, the weights he gave you are to heavy.
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Post by JonwayRider on Apr 29, 2011 16:25:12 GMT -5
they gave me 15gram weights. Too heavy? If they are, can I just remove 2 of them that are on opposite sides from each other?
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Post by JonwayRider on Apr 29, 2011 17:04:41 GMT -5
Ok, I just went outside and tried it again. Now it kind of hangs in 'mid-crank' and it tries to start but wont stay running. Too tight maybe?
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Post by JonwayRider on Apr 29, 2011 19:15:07 GMT -5
I'm at my wits end here. tried removing 2 of the rollers, which did nothing for it. Now it acts like it wants to catch but as soon as I let off the starter switch, it dies again. Sometimes it even hangs.
Anyone?
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Post by sprocket on Apr 29, 2011 19:48:46 GMT -5
It is not a variator problem.. you have something else happening...
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Post by JonwayRider on Apr 29, 2011 19:51:09 GMT -5
Any idea?
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Post by sprocket on Apr 29, 2011 19:54:11 GMT -5
Wrong sized belt? No Valve gap, electrical, or fuel related...
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Post by JonwayRider on Apr 29, 2011 19:57:56 GMT -5
Can I start the engine with the variator off and see what happenes, or is that a bad idea? I'm going to do an oil change and a carb clean tomorrow. As I dont have any feeler guages, I cant check valve gaps. Looks like I have a busy Saturday.
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