Variator assembly issues

[silverjcl07c]

Hello all. I have a 2007 JCL YY250T and I was having some some issues with the variator so I took it apart to inspect it, but when I put it back together, the large pin with the two black seals of some kind is sticking out about half a centimeter more than it should and the fan blade will not line up correctly with the variator itself. Any idea what I may be doing wrong to end up like that? Thanks

[inkyben]

any damage on the shaft splines?

[leo]

misaligned rollers.
after you install the rollers position the ramp plate in place.
the crank journal goes on with the variator
while squeezing the ramp plate and variator together install onto the crank and push it all the way back.
you might need to open up the clutch pulley a little to give the belt enough slack.

be careful about putting on the front part of the variator, it should engage the splines and should almost seat.

[silverjcl07c]

Thanks for the quick responses guys! I'm not sure if there is any damage to the splines but it did slide the ramp plate on by itself and it slid on with no problem. I had stripped the variator nut with an impact gun putting it back on the last time and had a hell of a time finding a nut for it and so much time went by I forgot how the whole thing went back together. . When you say misaligned rollers, I'm assuming you mean one side of the roller is supposed to be facing a certain way? These are OEM rollers and I couldn't not see a difference on either side do you not where I could get a picture to compare? Also I was not sure about the placement of those black seal/o-ring/spacer looking parts. There were two and I'm not sure where they both go.

[leo]

Oct 21, 2012 21:57:54 GMT -5 silverjcl07c said:

When you say misaligned rollers, I'm assuming you mean one side of the roller is supposed to be facing a certain way?

they roll from the center of the variator towards the inside edge.
if you don't squeeze the ramp plate and variator together when installing then the rollers will have a tendency to slide around and get dislodged from their pockets.
this in turn will prevent the belt and front face from being installed.

Also I was not sure about the placement of those black seal/o-ring/spacer looking parts. There were two and I'm not sure where they both go.

these are grease seals and one goes on the front of the variator the other on the back.
there should be a "groove" on the seals, it goes towards the inside of the variator.
there might also be a sleeve, make sure it's inside the variator before installing the grease seals.
fill the center inside of the variator with lub then insert the crank journal.
remember, keep the variator and ramp plate squeezed together the entire time or the rollers can become unseated.
also, be careful with the grease.
do not allow any to come in contact with the belt or pulley faces.

[silverjcl07c]

Thanks leo!. Also what I meant about the rollers facing a certain way was that I believe on aftermarket weights there is a lip or some sort of indentation on one side of the roller and it is supposed to be turned to face a certain direction when installed but I'm assuming that not the case on OEM rollers? Also I was squeezing the ramp plate when installing onto the spline until my hand wouldn't fit behind it anymore and for some reason that sleeve or pin is just sticking out about half a centimeter...I wont have time to give it another shot till the weekend but I will let you know my results. Thank you again!

[quicksilver]

If the sleeve is sticking out without the belt on, this is normal. The only time the sleeve will not be exposed is when the belt is sitting on the bottom forcing the two halves apart. As the belt rises on the faces, the two halves will move together and expose the sleeve. Hope this makes sense to you.

[leo]

Oct 22, 2012 18:49:34 GMT -5 silverjcl07c said:

Thanks leo!. Also what I meant about the rollers facing a certain way was that I believe on aftermarket weights there is a lip or some sort of indentation on one side of the roller and it is supposed to be turned to face a certain direction when installed but I'm assuming that not the case on OEM rollers?

like i said before, position the rollers so they are able to roll from the center of the variator towards the outer edge.
no other orientation is needed with rollers.

Also I was squeezing the ramp plate when installing onto the spline until my hand wouldn't fit behind it anymore and for some reason that sleeve or pin is just sticking out about half a centimeter...

the crank journal will stick out from the variator.

[silverjcl07c]

I had a chance to give it another try tonite and after 2 months of sitting it is up and running again! For some reason I didn't think the sleeve sticking out looked right but indeed it was. Thanks guys! I had a hell of a time finding those damn M14x1 variator nuts or I would have had it running a lot sooner. One more question I had is I was testing out something awhile back while fixing another problem and stupid me only finger tightened the variator nut and forgot to snug it down with an impact gun and the fan blade flew off when I started it and two of the fins broke off. Can this harm anything? Like cause vibration or less cooling or anything I should be worries about? Thanks. Also wanted to add I am pretty good with auto repair but motorcycles are new to me so I'm still learning.

[leo]

Oct 23, 2012 20:20:39 GMT -5 silverjcl07c said:

. . . when I started it and two of the fins broke off. Can this harm anything?

i've put quite a few around town and country miles on a variator with a broken fin.
two broken off might pose some problems.

Like cause vibration or less cooling or anything I should be worries about?

i didn't notice any abnormal vibration.
as for the cooling, i guess if all else fails you could use a fan ducted into the CVT cover.
there are a few different designs for these CVT covers, mine is metal and was not designed properly.
i had to drill holes over the variator so the case could breath.
if your case is completely sealed then you will also need an exhaust.
i would put it back by the clutch.

Also wanted to add I am pretty good with auto repair but motorcycles are new to me so I'm still learning.

these scooter engines are pretty simple and easy to work on if you got the right tools.

[binhpham]

Hi everyone,
I've been riding all my life but fairly new to scooter world, I have a Kymco GrandVista 250, saw some Ads by Malossi Performance Variator...my need is better acceleration ( not top speed )
My question is... how variator works ? hard to install ?
Thanks