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Discussion Starter · #1 ·
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So the newly aquired 400 history being unknown I decided to take a peek at the variator and clutch to see what was in there.
I had bought a new spring for the clutch and a new belt. stopped short of buying anything else as I wanted to see what was fitted. First thing was the variator, oh dear, seems like something went wrong in there resulting in me ordering a new variator.
Not sure what has happened, bike seemed to be running OK no major problems but clearly this one could not go back into service.
Good news is the clutch looks fine. So I'll give it all a good clean out and reassemble the clutch with the new spring fit the Dr Pulley variator when it arrives and box it back up with the new belt in place, good job I checked it.

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Daaang, this shows how tough this bike is, all that damage and still running at least marginally well
 

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I'm thinking whoever went in there last did not hold the variator faces together when they reassembled it and some of the rollers dropped out of place before tightening the nut. I'm sure whoever was driving it knew something was wrong but drove it anyway.
 
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Clearly the previous owner was not a maintainer, possibly worth the effort to disassemble rear pulley assy., check internal bearings, guide pins, re-lube, etc., can't really picture it being ok, after seeing that carnage. Here's a PSA* diagram just for general info.
I'm sure whoever was driving it new something was wrong but drove it anyway.
Not sure what has happened, bike seemed to be running OK no major problems but clearly this one could not go back into service.
Clearly not a normal failure, but definitely a neglect failure, the rollers simply were worn beyond the minimum gap of ramp plate, that one was clearly worn more as seen in pic and simply slipped out of place, rollers do not wear evenly, especially when there's a lot of dust, etc,.(neglect). Love to see the variator inner pulley carnage :(

Here's a PSA* diagram of rear pulley assy., just for general info. do this at every belt change and you will be ok, the rear pulley is very neglected on scooters. * Public Service Announcement


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Discussion Starter · #6 ·
Thanks for that ZRX. Clutch to my eyes looks OK.
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Case was a tad grubby but has cleaned up OK. I have a new yellow spring for the clutch so I'll split and fit that.


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New variator should arrive tomorrow. Transmission oil is good. Anything else to check?
 

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Thanks for that ZRX. Clutch to my eyes looks OK.
The only way to truly check that rear pulley assy. is in good operating condition and properly, is to disassemble clean, inspect, lube internal components, not sure how one determines is serviceable otherwise, "Looks OK" from the outside does not reveal much, yes, the part of the clutch shoes that I can see looks ok, but I can also see a mark, were apparently a chisel and a hammer where used to remove/install clutch retaining nut :unsure: , if that's the case and based on what I already seen, in kind of shows some unorthodox mechanics worked on it :unsure: I would not hesitate to at least take a look at internal bearings and regrease. BTW a light scuffing on all pulley faces with green or red scotch-brite pad is always recommended when replacing the belt.
 

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Discussion Starter · #8 ·
Yep I will be stripping to fit the new spring so will give it a good looking at. When in UK I would replace all bearings as they are readily available from all over the place, (industrial North East) but here in Spain not so easy to locate so I'll just check all is well.
 

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Discussion Starter · #10 ·
Well to my untrained eye the rest of the variator looks OK. However that bushed part is very sloppy on the spindle, lots of play so I'm sort of glad I was pushed down the new variator route with the other damage.
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Discussion Starter · #11 ·
Well it's all boxed up and back on the road, need to give it a run out to see what it;s like but up and down the road all seemed OK. Would have been nice to change all the clutch bearings but I'll get some when I'm back in UK. The Dr pully variator caused a bit of a panic. When fitted I tried to fire the bike up to check operation only to hear a hell of a din from the variator.
When spinning the variator was catching on some of the internal webbing on the inner case. I had to take the angle grinder to the webbing and shave a few mm off to create enough clearance, not sure what was going on there. I should have taken a few pictures but was too keen to get it back together. Anyway all is good for the moment.
The Dr Pulley sliders are a different size to standard being 29 x 18.
I'll report back when I've taken it out for the day.
 

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Discussion Starter · #12 ·
Had a nice ride out up in the hills, all seem good. I had ordered a Givi airflow from an on-line motorcycle warehouse in Alcoi so had a run up to collect it. Took the standard screen off before I went and fitted the new screen when I picked it up. Impressed with the airflow on the way back, much better than the standard screen, easy to adjust. So hopefully will just enjoy useing it alongside the 650 for a while.
 
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