Higher RPM Clutch Engage

[TBR125]

Thanks Iahawk for the inspiration. I tried an ebay clutch holder to no avail. $3.27 for a 36inch clutch holding tool beats online prices and it came right off without breaking a sweat.

Now I've got to buy a 39mm socket.

[JJJoseph]

Thanks Iahawk for the inspiration. I tried an ebay clutch holder to no avail. $3.27 for a 36inch clutch holding tool beats online prices and it came right off without breaking a sweat.

Now I've got to buy a 39mm socket.

There are no 39mm sockets!  You have to use a 39mm (or 32mm on some bikes) box spanner.  If you search for "39mm spanner" or "clutch nut wrench" on Google, lots of choices will pop up. They're cheap, only used for scooter clutches.

For the main nut holding the clutch onto the drive shaft, a simple electric impact wrench takes it on and off.  Don't over-tighten on re-assembly!

[JJJoseph]

I've never paid a lot of attention to the various clutch pad springs available...but it seems like they are always color coded to their level of stiffness (soft, medium, firm)..how stiff are they, exactly? who knows!

Clutch springs are color-coded, most commonly blue,red,yellow (high rpm). I prefer yellow springs to allow a little "space" off idle, before the clutch engages at about 4000rpm. 

[Stig / Major Tom]

A 1.5" socket was pretty easily 'persuaded ' onto my big clutch nut.

Stig

[TBR125]

There are many 39mm sockets. Their primary purpose is for front axle nuts on fwd vehicles. I bought a 39mm 1/2 inch drive socket to use with the impact gun and the nut came right off. I believe the correct color order is blue, yellow, red (if I am not mistaken) with the red being the most "Sporty".

I used a red contra spring and red clutch springs. The clutch engaged at 2100rpm with the old springs but at 4600 with the reds. I might drop to yellow after I do some more extensive testing. With the stiffer contra spring the bike climbs a lot better but I may have lost too much top speed. I will check tomorrow when there is enough light to read the tach at speed.

I used caliper grease on the pins after cleaning everything and also greased the needle and ball bearing with good old lucas green high temp. It was my first clutch service on the bike and I got it done in 2 hours ready for driving to work in the morning. The future 155cc bbk will be pushing my overnight service window.

[Iahawk]

TBR - glad it worked out for you!

[de dee]

I used a disc brake from a 1/2 ton pick up it has a hole the right size for the 39 mm. socket, and you can put your knees on the side to hold it from popping up,  robot from scooter west did a show on removing that nut, and he could put his feet in the side to compress the spring, if I tried that I cannot reach the nut, too old,.  cant bend,.  when you take the nut off mark it ,  so you can retighten it to the same spot + just a tad more, 1/8 of a inch,  no more than that,

[scooterfan]

I used a red contra spring and red clutch springs. The clutch engaged at 2100rpm with the old springs but at 4600 with the reds. ............With the stiffer contra spring the bike climbs a lot better but I may have lost too much top speed.

My Agility’s clutch actually had a red contra spring when I bought the scooter.  I bought the scooter 2nd hand so I’m not sure whether the spring had been intalled by the previous owner. Most of the red paint were gone, so maybe the spring was 2nd hand.

The new Chinese clutch came with a spring with no color - it’s just bare metal. I think the Chinese spring without color is probably stiffer than the red spring at my original Kymco clutch - because climbing ability is also a lot better since the Chinese clutch has been installed. Maybe the red spring at my original clutch has lost some tension by time.

I tried a little bit of grease on the Variator rollers but the grease has been removed in the meanwhile - it did not make any difference.  In fact - almost all grease found it’s way out of the vatiator. Fortunately nothing ended up on the belt or pulleys.

[Stig / Major Tom]

De dee's comment made me laugh.
I could put the impact gun on the clutch, or my feet.
Never both.
I opted for the impact gun paired with closed modular Nolan helmet😊
Very exciting!
Stig
*it was possible to hold it closed with one manly hand...and thread the nut back on with the other....though an assistant would have been helpful at that point.

[TBR125]

My Agility’s clutch actually had a red contra spring when I bought the scooter.  I bought the scooter 2nd hand so I’m not sure whether the spring had been intalled by the previous owner. Most of the red paint were gone, so maybe the spring was 2nd hand.

The new Chinese clutch came with a spring with no color - it’s just bare metal. I think the Chinese spring without color is probably stiffer than the red spring at my original Kymco clutch - because climbing ability is also a lot better since the Chinese clutch has been installed. Maybe the red spring at my original clutch has lost some tension by time.

I tried a little bit of grease on the Variator rollers but the grease has been removed in the meanwhile - it did not make any difference.  In fact - almost all grease found it’s way out of the vatiator. Fortunately nothing ended up on the belt or pulleys.

The stock springs on my agility were red but not the same as the Koso reds. The stock red felt a little lighter than the yellow Koso.

[scooterfan]

.................... The stock red felt a little lighter than the yellow Koso.

Thanks for mentioning. I have a sensitive scale - maybe I can compare weight and spring tension in future. It would be interesting to know exactly why the scoot perform better when riding uphill. Top speed might be lower but I never ride long distances or at high speed. So lower speed would not bother me.

[TBR125]

The contra spring keeps the cvt from up-shifting until a certain torque is reached. The red contra is too stiff (keeping the engine at 6800rpm which is way above max torque at 5500) so I will drop down to the yellow spring. Also the red Koso clutch springs firmly engage the clutch at 4300rpm which is too high for my riding preferences. I will try the yellows which should drop it to 3600-4000rpm.