Dr Pulley sliders disaster

[xsel777]

It was great while it lasted.

The photies say it all.

Outer variator face (new)  lost all it's splines, and is totalled.
New sliding pieces melted.
The sliders melted.!
The nut washer disintegrated.

To be totally transparent, I had moved the spacer from inside the outer face to outside, so, effectively 2 washers held down by the nut.
Also, for the first time I used a torque quench to tighten the nut.
I felt it was not tight enough, so added another  10 nm.
The nut came off fairly easily, but had not actually spun off.
The outer variator face was wobbly, since the one washer had disintegrated and the this same outer face splines are also gone.

Back to rollers then.

I still have the old sliding pieces, so I  just need someone to clean up the crank splines which are not looking that great, and then a new nut washer and let variator face, then we are back in business!

Luckily I just got paid out for a claim, so have some spare cash.

Is there a tool that can do the crank spine cleanup?

 

 Sent from my Samsung Note 3 with Tapatalk

[de dee]

  did the cogs on the ramp plate grind off too,.   if so that's what caused the outer face to grind off the cogs,.  to much torque for it,.   a new ramp plate could be used to clean up the drive shaft, slide it in and out on the shaft  ,. is the boss frozen in there ,. looks like the ramp plate sliders took a beating too,.  any ideas from you,.  from looking at it,. 

[xsel777]

The back plate cogs are ok, it has recently been replaced. I have an old face plate I can use to clean up the crank splines but not sure how effective that will be as face plate aluminium while crank is steel.
The boss is ok. Some silicone spray got that off.
Is there supposed to be some lubrication on the boss?
If yes, what type?
Luckily I still have my old sliding pieces which were  still quite good condition.

 Sent from my Samsung Note 3 with Tapatalk

[sissy mary]

I bet you put the inner most thick washer in back wards? It has a beveled side and a flat side. The beveled side go's in facing the motor. Doing this will screw up everything because it is not aligned correctly. 

[sissy mary]

Also, never change washer or anything else around but in it's correct position as it was put together at the factory. Using stock kymco parts your belt rollers and such can last over 30,000 miles. Use non stock will often get you down the road maybe 1-200 miles before KA-BOOM!  Have you not learned from me and Bongo man. We tried and failed miserably. Don't do what we tried to do when we were young and stupid. HA HA, just a joke Bongo-dude. 

[de dee]

The back plate cogs are ok, it has recently been replaced. I have an old face plate I can use to clean up the crank splines but not sure how effective that will be as face plate aluminium while crank is steel.
The boss is ok. Some silicone spray got that off.
Is there supposed to be some lubrication on the boss?
If yes, what type?
Luckily I still have my old sliding pieces which were  still quite good condition.
no grease on the boss,  a little on the spline shaft  full syn. grease high temp.,  so it wont get to the belt,

[Stig / Major Tom]

By your post's title it seems to imply a  problem caused by the sliders.
But are you saying that the assembly came loose because a washer exploded after being crushed by overtightened nut?
I just have never heard of a washer breaking! Wow.
Would have thought that the shaft or nut would have failed first while you were overtightening.
Stig

[bongoman]

You are spot on, Sissy Mary. Older, perhaps a bit wiser. Definitely not going down that road again.

[xsel777]

Amazingly, in South Africa, overnight freight actually worked.
I cleaned up the splines, it was an ideal time to stock up on some new files, and it was not really difficult, just a bit finicky is all.
New Parts are fitted, and "the beast" (stolen nickname) is motoring again...
Now we are working on another exhaust, the Suzuki 700 one is getting too loud, and the aluminum warped from the heat. Where the mounting band sits.

I have another BMW f800gs can,  which the exhaust place up the road will modify to fit.
I liked the sound from the last one I had fitted, a nice deep growl, I really felt my testosterone levels where higher with it.. 😉

 

[xsel777]

The wire is there because the original BMW mounting band is also being modified.

 Sent from my Samsung Note 3 with Tapatalk

[xsel777]

Here is a pic of the BMW F800GS can with original mounting band which still needs a lot of love but working for now. The original mount point can be seen above the can.

With only  a 5 mm space there, I am nervous, so will grind a 45 degree angle off the bottom of that mount point to increase the space.

[xsel777]

Now with new made up s/s band welded to original BMW mount mechanism ,  because it looks good.

 Sent from my Samsung Note 3 with Tapatalk