How to Change Your Belt! :D

[vespa50sp]

Nice write-up. I'm about to install Dr Pulley sliders and a new drive belt on my People s250. I picked up a Harbor Freight electric impact wrench for $40 after their standard 20% off coupon on one item. I was surprised at how cheap the Kymco belt was, $60 with tax, and it has a pretty good rep also.

[Vivo]

Thanks for sharing! Great one! 

[ScooterCommuter]

The other thing I'd rec here (for all similar scoots) is, while you have the cover off, clean and lube the kickstarter, particularly the secondary gear. belt dust tends to accumulate there, binding the secondary gear to its retainer spring and the kickstart lever shaft tends to corrode and bind up if you dont use it often. You dont want to be caught with a dying battery away from home and a scoot that you can't kick over...

[Vivo]

You dont want to be caught with a dying battery away from home and a scoot that you can't kick over...


If my battery is low and can't turn the engine...I cannot anymore use my kick start... because I have a DC CDI.... won't work without a good battery....  I wonder what my kick start is for?     With an AC-CDI, you can kick start if the battery is low or even dead...

[ScooterCommuter]

If my battery is low and can't turn the engine...I cannot anymore use my kick start... because I have a DC CDI.... won't work without a good battery....  I wonder what my kick start is for?     With an AC-CDI, you can kick start if the battery is low or even dead...

You've still got enough juice to generate a spark when the battery is too low to crank it. Only just enough,  but without the extra load of having to turn the engine as well it will start. Of course if it's completely dead then yes, you're out of luck.

[Vivo]

You've still got enough juice to generate a spark when the battery is too low to crank it. Only just enough,  but without the extra load of having to turn the engine as well it will start. Of course if it's completely dead then yes, you're out of luck.

As per experience with a weak battery in a DC-CDI ... the scoot can't start when using the kick start... the horn and lights turn on, but can't create a spark to start the engine.... just can't...

[garicao]

Great tutorial!

Only thing I'd add is that (on the 2-stroke People 50, at least), the new belt width is 18mm and the used belt service limit is 17mm, as per shop manual (well, elsewhere in the manual it says limit is 16.5mm).  So, you can measure first, then know if belt replacement is necessary or optional.

Cheerios,

--garcia

"We're lost, but we're making good time."

[mcdcfc3]

Thanks for taking the trouble to post this. It's great to see how it's done but it's also made me more convinced to leave it to the experts such is my lack of skill with anything of a technical nature

Sent from my Nexus 7 using Tapatalk

[paceneedsstides]

Is this the people 50 you're going to sell to me cheap or donate to the Club on FB lol

[MJR]

3) Do I really need an air-impact wrench?  All I've got is elbow-grease.

I made a holder bar for another project on my Burgman 650 that should work. It's just made from some metal bar and some bolts. It looks similar to this but just a Y shape.

[mousejunks]

I use an electric impact wrench for loosening, and the variator holding tool + hand wrench for tightening. Make sure you aren't tightening the variator face against the belt. At the same time I also clean out the rest of the case, last time a teaspoon of black dust came out of the rollers.

[Mr. Paul]

It is not necessary to remove the rear clutch assembly. If you have a reasonably strong grip, you can put your hand in the rear pulley and move the faces apart as you pull the belt deeper as if it were in a higher gear. That gives you more than enough belt slack to remove the front variator and replace the belt. Hope that helps.

[Stig / Major Tom]

A tip:
The cheap 12V impact wrench from Harbor Freight will break loose both of the CVT nuts using only a 12V scooter battery!
Surprised the heck out of me - thought I'd have to hook it to a non-running-car battery......but the scoot battery had enough poop to knock both of the Burgman 400 nuts loose.
Stig