Dr Pulley 14g install

[agilebda]

I have used and experimented with the Dr Pulleys for some time now. I have 3 kymco GTI scoots and I experiment on all 3. The best rollers are the OEM in my opinion. I actually found a 14 gram roller which I find better than the Dr Pulleys
http://www.ebay.com/itm/231110647711?ru=http%3A%2F%2Fwww.ebay.com%2Fsch%2Fi.html%3F_from%3DR40%26_sacat%3D0%26_nkw%3D231110647711%26_rdc%3D1

I find that the mid range and low end torque is lost with the Dr Pulleys.

[agilebda]

Im building another GTI at the moment and planning on using a contra spring and HIT clutch system. I will let you know how this runs. Should be a ballistic combo with a Zard Exhaust!

http://www.ebay.com/itm/KYMCO-DOWNTOWN300-350-XCT300-400-XCITING250-TECHPULLEY800rpmTORQUE-CONTRA-SPRING-/141612614846?hash=item20f8c504be:g:CqAAAOSwqu9VDl14&vxp=mtr

http://www.ebay.com/itm/KYMCO-XCITING-250-300-DR-PULLEY-HIGH-PERFORMANCE-CVT-REAR-HiT-CLUTCH-HiT231801-/131637569285?hash=item1ea635e705:g:rNUAAOSwo6lWLa95&vxp=mtr

[zevsdad]

Thank you so much for this very detailed exlanation-I will build this!

One question -what is the semicircular notch on the right hand side of the tool for?

[Abner_Bjorn]

what is the semicircular notch on the right hand side of the tool for?

   I originally made this for my Yamaha C3.  That notch locks on top of the center stand.   

[Yellow Jacket]

Here's my cheap, home made holding tool. Get about 3 feet of 1/4 X 1 inch flat stock from Lowe's. Drill and tap two 1/4-20 holes near the ends. Cut to about 1 foot. Now you have 2 pieces, 1 foot and 2 feet long. Drill 1/4 inch holes for the hinge. On the pivoting arm I put a nut on the bolt to make both bolts the same height. I had to file the two bolts down just a little to get them to go into the holes on the outer part of the variator. That's it. Since it's adjustable I can use it for other applications.

[zevsdad]

Wow=that looks incredibly simple yet effective! I'm guessing you hold the longer end with your other hand-or with your foot maybe?

[Yellow Jacket]

Usually I can put the long end against a fixed part of the bike, i.e., the clutch bell, side stand etc. Cheap and does just what it need to.

[zevsdad]

I'm reading now that the nut must be tightned to factory specified torque--requiring a torque wrench to measure the exact torgue. Does anyone know the factory specified torque measurement for the 17mm variator nut?

Also, if I do get an impact wrench, will I still need to hold onto the pulley or the variator when removing the nut with an impact wrench?

Thanks

[Abner_Bjorn]

The torque should be somewhere North of 70lbs on your 300.  It is okay to go tighter.  There is a lot posted on Variator nuts coming loose on the SYM forum.  The most important thing is to be sure your belt is out of the way when you tighten it.   An impact wrench will move the nut (on or off) without having to hold the variator.    I use a 12V impact wrench from Harbor Freight.  It clips to your battery terminals.  It was around $25, and works great for variator and clutch nuts.  I put a sharpie line going across the shaft and the nut.  When I tighten, I go slightly past the line.  I prefer to use the holder and the torque wrench, but have worked on a couple of scooter that did not have the indentations on the outer drive face. 

[Yellow Jacket]

Torque spec according to the service manual is 93.1 NM, which converts to 69 ft.lb. Impact works great to remove the nut, no holder needed. Putting the nut back on with an impact is risky. You DO NOT want to pinch the belt. I use my holder and ratchet the nut on. When it starts to pinch the belt I remove the holder and slowly keep tightening. At some point you will start to turn the motor over. This will loosen the belt. Once again, use the holder and tighten the nut a few turns. When you meet resistance, repeat the above. Just be patient. Once the nut is seated, use the holder and torque the nut.
Here's a link to the full service manual.
http://www.kymcousa.com/owners/onroad/People-GT-300i-Service-Manual.pdf

[zevsdad]

Thank you! - this is great info- you guys are awesome.

[zevsdad]

Sliders came in - I got a torque wrench and some materials to build the tool. I am almost ready! Wanted to check with you guys before proceeded though--are these the correct sliders?

[de dee]

yes they are good, 20/12  14 gram  ,.  look in the bottom of case you will see how to put them on, 
when you make your tool have the long piece long enough to hit the floor so it will not slip,

[zevsdad]

Well- I am happy and proud to report that I completed the install! I really could not have done it without all of your expert help-so thanks guys!
the paper crunch sound appears to be gone! there is a smoothing out sensation I can feel- and the sound of the engine is deeper now. When I come to a stop it is MUCH smoother. Anyway-thanks again!

[Abner_Bjorn]

Well done!  Good feeling isn't it?  I'm a firm believer of wrenching on what you ride.   Sure is a good looking variator holder you have there.