[bornagainbiker]

I have just serviced my K8 400 with 31k. The variator moving plate was clogged and all the rollers had flat spots.
After fully cleaning I installed some new non oem 26x13 17.5g rollers. The 5 pad clutch still had plenty of thickness and the belt looked ok, however I did not have a digital vernier to check the thickness. (One now on order).
On re assembly at tick over there is now the dreaded roller rattle which is fairly loud and It disappears at 2000+ rpm. The bike pulls and works excellent so there are no real mechanical problems, just the loud clatter at tick over.
I stripped it again and re checked? I reinstalled the old rollers and they now also rattle? I put the new rollers back in.

Why prior to the service was there no loud roller rattle?
Could the nut not to the correct torque be doing this as I used a 12v Impact gun? Done 150 mile and ok.
Could the belt even though looking good be over worn and below width spec? I'm to believe its 24.1mm minimum from a new 26mm?
Could the rear of the movable plate where the rollers sit be over worn?
I know the benefits of the DP sliders but would they be better, purely for to eliminate the rattle?

I recently met a chap with a 250 scooter and he said he had the exact same symptom but his was even louder than mine. He took it to a mechanic and they said 'They all do that, after fitting new rollers, and will get better after a few thousand miles!' Could this be for the dust to build up again and dampen the rollers?

I have read one post where fitting a new belt cured the rattle? Could this be the belt being wider pushing the movable plate further in by say 1-2mm, thus making the rear plate tighter against the rollers?

I'm living with it but annoying. Just waiting for the digital vernier to check the belt before possibly having to order a new one, the oem belt is £160 ($240)! But Malossi Kevlar is £90 ($135).

Your advice and tips would be appreciated. Thanks, Colin

 

[Ralph M]

I think it's the dust I cleaned mine out and went from sliders to rollers and while I think
sliders do run quieter I think cleaning out the dust is what make the most difference,
I certainly noticed it when I started it after the clean out but it's not bad just that it was not
there before.

 

[bornagainbiker]

Ralph, a couple of questions?

1. Why did you go back to rollers from the DPS, I think you had 18g?

2. Where did you get the Gates drive belt and cost?

Thanks

 

[Ralph M]

PM sent

 

[Daboo]

...Could the nut not to the correct torque be doing this as I used a 12v Impact gun? Done 150 mile and ok...

My guess from what you're saying is the rattle is from the dust being gone. If it goes away at 2000 rpms, then the only time you'll hear it is at idle.

Regarding the nut, did you use a socket wrench to turn the nut with through a couple engine compression cycles? If not, you've torqued the nut while the belt is pinched, and once you started, the nut is now loose and ready to fly off. If it comes off, it'll cost you several hundred dollars to repair.

Chris

 

[bornagainbiker]

...Could the nut not to the correct torque be doing this as I used a 12v Impact gun? Done 150 mile and ok...

My guess from what you're saying is the rattle is from the dust being gone. If it goes away at 2000 rpms, then the only time you'll hear it is at idle.

Regarding the nut, did you use a socket wrench to turn the nut with through a couple engine compression cycles? If not, you've torqued the nut while the belt is pinched, and once you started, the nut is now loose and ready to fly off. If it comes off, it'll cost you several hundred dollars to repair.

Chris

No Chris I made sure that the belt was not pinched whilst tightening the nut. It's free, as when it was still open, I ran it up to see the belt move, then I re checked the nut before replacing the cover etc.

Just had a tip from a scooter mechanic and he instantly asked if I also replaced the 4x dampers on the movable plate? As he always changes these also and has never had roller rattle after cleaning and roller replacement. My answer was no I did not replace them. Sounds logical, they are called Dampers after all. Suzuki UK want £6.40 each where on the USA microfisch sites they are only $4.84 each, double the USA price. Rip off Britain comes to mind yet again. I may buy the dr pulley dampers for €17.90 (£15) + postage.

 

[Daboo]

I've never replaced those. The first 400 had 49,000 miles and the current 400 has 26,000. Do they look worn?

Chris

 

[Ralph M]

Sent the reply as a PM before seeing you had posted the same question on here as well
but if you want to copy and paste my pm reply it's up to you and may help UK members.

 

[bornagainbiker]

Sent the reply as a PM before seeing you had posted the same question on here as well
but if you want to copy and paste my pm reply it's up to you and may help UK members.

Ralph, a couple of questions?

1. Why did you go back to rollers from the DPS, I think you had 18g?

2. Where did you get the Gates drive belt and cost?

Thanks

by Ralph M

The sliders flipped over at about 5000 miles and the revs went up, when I stripped it
I found lots of dust and think the sliders had flipped over due to this but did not fancy
putting them back incase it happens again, though I am now thinking of refitting them,
if I were to buy again I would go for 19g ones I wanted those at first but non were available
at the time. The Gates belt came from

http://jim-allan.com/

£70 delivered it seems looking at it to be stronger than the org one but it as less than 300
miles so cant tell yet how it will go on, the org one was in spec at 14000 miles but was just
showing signs of minor cracking just were the teeth join the belt but I would think it would
have done at least another 5000 miles,

 

[Ralph M]

I said in my pm they flipped at 5000 miles but it was nearer 6500.
No flat spots on the Suzy rollers with 7500 miles on them, there was
some slight ware on the sliders at about 6500 miles but not enough
to worry about.

 

[Ralph M]

If you have any problems with jim Allen e-mail Greg
he is very efficient and does exactly what he says he will.

 

[bornagainbiker]

I've never replaced those. The first 400 had 49,000 miles and the current 400 has 26,000. Do they look worn?

Chris

TBH Chris, I never really checked them. I took them off, gave them a clean and put back on. I asked a question about renewing these dampers on a DPS post and as you have again stated you have never replaced these. :roll:

 

[bornagainbiker]

If you have any problems with jim Allen e-mail Greg
he is very efficient and does exactly what he says he will.

Thanks. He has just called me and £26 for the 4x Dampers and the belt is £65 plus postage.
Hmm. Not sure if I need the dampers now? On a tight budget and costs are rising.

 

[Ralph M]

I did not fit new dampers as I could not see any ware at all on them, I think
the rattle is the rollers.

They charged me £70 all in so expect £5 postage

One thing I found was when I tightened the variator nut using
a electronic torque wrench the tell tail paint lined back up exactly.

 

[DoubleJ]

Just had belt and rollers changed out at 28000 K's . Also changed the dampers. No obvious wear was discovered on either the rollers or dampers but changed anyway. All is quite and normal in the CVT. Runs like a new bike. Considering the k's I was surprised at the lack of black dust in the CVT. 3 shoe clutch still has lots of pad material left and no issues. Must be the way I ride by taking off hard and then backing down. Lots of 2 up riding highway also.

 

[bornagainbiker]

New Gates belt ordered at a good price of £65 + £5 postage (Thanks Ralph for the contact), will let you know the outcome when fitted..... trying the new belt first and decided on not getting the oem dampers just yet as £25 a set. If it still rattles then I will get the DPS and their dampers as a set.

 

[Ralph M]

Let us know how you get on, mine as always revved higher than others report from new,
no matter if it is fitted with rollers or sliders.

 

[bornagainbiker]

Let us know how you get on, mine as always revved higher than others report from new,
no matter if it is fitted with rollers or sliders.

Currently I get 60 at 6000, 70 at 7000, 80 at 8000.

 

[Ralph M]

When new it ran 5750 at 60 at 70 it was 6550 and 80 was 7500
Fitted with 18g sliders it ran 5500 at 60, 6200 at 70 and 7000 at 80
At the moment it is doing 5700 at 60, 7200 at 70, don't know what it's doing at 80.
When you watch some of the Utube vids of Burgman's flat out they often have
the rev counter buried in the red.

 

[cliffyk]

All,

Mostly curious, are you reporting actual or indicated speeds?