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Author Topic: Changing the Variator  (Read 8289 times)

paali10

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Changing the Variator
« on: June 13, 2012, 12:50:32 PM »
Hi, Im gona change my variator to a Malossi Multivar with 5.1 gram rollers.
I have gotten into the variator, but cant seem to open the main nut..
How do I open the main nut on the Agility 4t 50?

Thanks
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wordslinger

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Re: Changing the Variator
« Reply #1 on: June 13, 2012, 01:25:14 PM »
..i now use a 19.2 volt cordless impact wrench, however for years i used these 11-R clamps to  hold the drive face, while i attacked the nut with a 17mm, 1/2" drive socket and ratchet...
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streido

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Re: Changing the Variator
« Reply #2 on: June 13, 2012, 01:48:11 PM »
Same as Word, i use an impact wrench, couldnt get it off any other way tho i did try about 2-3 other methods. Its much easier using the impact wrench, they are not much more expensive than the special variator removal tools and you can also use it on your rear pulley too.
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REDKYMCO

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Re: Changing the Variator
« Reply #3 on: June 13, 2012, 01:55:37 PM »
I purchased a 12v brand new cougar impact wrench from eBay for 19 pounds with free delivery and it also comes with 4 impact sockets including a 17mm one, to power it just connect to your car battery or other 12v power source, with it being a impact wrench there should be no need to lock the variator to loosen the nut. If the cougar one is not available there are RAC ones available on eBay but a little dearer just search on ebay for RAC 12v impact.
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paali10

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Re: Changing the Variator
« Reply #4 on: June 13, 2012, 04:17:35 PM »
Okey, here is my next task. I need to change the contra spring..
Where do I get the tool for that?
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Kenho21

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Re: Changing the Variator
« Reply #5 on: June 13, 2012, 04:29:51 PM »
@wordslinger- so you just line the teeth up and put the clamp on then hold it with your hand while with the other you loosen the nut?
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2009 Kymco Agility 50- 72cc Airsal kit, Uni Free-Flow Air Filter, Main Jet 120, 1500 Contra Spring, 6g Rollers, Malossi Multivar Variator, NCY Exhaust, NCY 80cc Camshaft, Cut CDI, Smooth Boss Drive, MRP Ignition Coil

streido

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Re: Changing the Variator
« Reply #6 on: June 13, 2012, 04:31:18 PM »
I use my torque wrench to remove the bell cover nut then remove the whole rear pulley. Then i slip an oil filter removal tool (£8) over the clutch, making sure i dont damage the clutch pads. This holds the clutch then i use a large adustable spanner to loosen the big nut that hold the clutch on to the rear pulley.

Make sure the filter tool is the metal band type, not nylon and def not the chain type. Mine is like this,
 http://www.renault4.co.uk/technical/oil-change-tools.jpg


Remember to put some threadlock on the threads for the variator and clutch when your refitting the nuts, stops them working loose.
« Last Edit: June 13, 2012, 04:33:19 PM by streido »
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wordslinger

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Re: Changing the Variator
« Reply #7 on: June 13, 2012, 04:34:20 PM »
..yup..just try to align arms 180 degrees apart, for better grip..

..i usually lodge the handle against my boot as i'm pulling up counterclockwise on the ratchet handle...

..if it's never been loosened before, the first time might be a bit tight...

..if it tends to slip, turn the 11r around the opposite way
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paali10

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Re: Changing the Variator
« Reply #8 on: June 13, 2012, 09:29:17 PM »
So, I just put together everything (the variator and clutch) for the 2nd time.. and I was missing the plasitic bit that came with the variator, so it didnt go forward.. only a wierd noise.. Where do the plastic bit go?

Also I would like to know how the rollers are supposed to be.. Been trying to look it up, but cant find how.. Right now I have then with the Malossi logo facing forward..

Thanks
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streido

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Re: Changing the Variator
« Reply #9 on: June 13, 2012, 09:51:59 PM »
Quote from: paali10 on June 13, 2012, 09:29:17 PM
So, I just put together everything (the variator and clutch) for the 2nd time.. and I was missing the plasitic bit that came with the variator, so it didnt go forward.. only a wierd noise.. Where do the plastic bit go?

Also I would like to know how the rollers are supposed to be.. Been trying to look it up, but cant find how.. Right now I have then with the Malossi logo facing forward..

Thanks

Do not run it without the plastic bits on the variator, it will wreck it in no time. You can buy spare ones if you lost yours, just look for variator guides or ramp plate guides and you should find them. I saw some new ones on ebay last week for under £4.

Most rollers can go in either way round, some have a slightly thicker end tho that are meant to go in one way.

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paali10

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Re: Changing the Variator
« Reply #10 on: June 13, 2012, 10:04:55 PM »
Okey thanks, I still have the plastic ring that I got with it.. But I dont know where it goes.. Didnt find the right drawing in the manual or internet..
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paali10

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Re: Changing the Variator
« Reply #11 on: June 13, 2012, 10:24:33 PM »
Please answer
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blue

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Re: Changing the Variator
« Reply #12 on: June 13, 2012, 11:11:41 PM »
that plastic ring snaps on the outside of the plate just befor you put the bold back on. make sure all parts are there even theam 3 little v like things with out you well find out soon to soon.
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wordslinger

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Re: Changing the Variator
« Reply #13 on: June 13, 2012, 11:59:32 PM »
..you do not use the plastic ring that comes with the multivar...


..frow it away!!!!
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wordslinger

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Re: Changing the Variator
« Reply #14 on: June 14, 2012, 01:03:35 AM »
So, I just put together everything (the variator and clutch) for the 2nd time.. and I was missing the plasitic bit that came with the variator, so it didnt go forward.. only a wierd noise


..well, that's not good at all..

..can you post some pics, for something is amiss...
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