CVT Manual

7/25/2019 CVT Manual

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HOW TO CLEAN A CONTINUOUSLY

VARIABLE TRANSMISSION (CVT)


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Introduction

Scooters, like any other vehicle, require regular maintenance to remain in good, working condition for as longas possible. Cleaning the continuously variable transmission (CVT) is required to keep the scooter running

properly. If the procedure is not completed every three to four months, the CVT could become clogged with

dirt and grime. A clogged CVT could keep the scooter from working properly, or at all. Any scooter ownerwho wishes to maintain the quality of life for their scooter, should use the following guide to clean the

scooters continuously variable transmission.

The following guide will show how to remove, clean, and replace a continuously variable transmission. The

process is quick, easy, and only requires a few tools. The procedure can be completed wherever there are

tools. A garage is the simpler location choice, but there are no harmful or staining fluids involved in cleaning

a CVT, so the procedure may be performed in any desired location with room enough to reach the scootersCVT parts.

The CVT cleaning process involves many loose parts, bolts, and screws. Designate a safe place for loose part

storage when removing the CVT components. Ensure the loose parts are not lost or mixed up, to prevent anymishaps when replacing the CVT components.


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Using anything other than an impact gun

or strap wrench will damage the CVT

components.

What You Will Need

(a)Phillips Screwdriver

(b)8mm Socket Wrench

(c)10mm Box End Wrench

(d)Impact Gun (or Strap Wrench)

(e)14mm / 17mm Socket Attachments

Items not pictured:

(f) Paper Towels or Rag

Step 1: Remove Kick Start Lever

i. Unscrew bolt on kick start lever with a 10mm

box end wrench.

NOTICE


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Loosen all bolts before removing the

bolts entirely. If bolts are removedindividually, the CVT cover may crack or

warp.

Step 2: Remove Air Box, ifnecessary**This particular scooters air box partially overlaps

the CVT cover. The air box must be removed beforeattempting to remove the CVT cover.Ifyour

scooters air box does not interfere with the removal

of the CVT cover, skip to step 4.

i. Unscrew all four screws attaching the air box

to the scooter, using a Phillips screwdriver.

ii. Place screws in a safe area to prevent losing

any.

iii. Pull air box from the scooter and set aside.

Step 3: Remove CVT Coveri. Place 8mm socket wrench on bolt in a

horizontal position.

ii. Rotate socket wrench approximately 90o

counterclockwise, just to loosen the bolt.

iii. Repeat steps i and ii for each bolt.

iv. After all bolts are loosened, completely

remove bolts with the 8mm socket wrench.

v. Set bolts aside.

vi. Pull off CVT cover and set aside.

NOTICE


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Tapthe impact gun trigger when

removing bolts. Holding the impact gun

trigger will cause damage to bolts andother nearby components.

Do notuse liquids to clean CVT or its

components. Liquids will damage the

pulleys and prevent proper functioning.

Step 4: Remove Front and Rear Pulley

i. Remove front pulley bolt with impact gun and

17mm socket attachment.

ii. Set bolt aside.

iii. Grip rear pulley with one hand to preventspinning while using the impact gun.

iv.

Remove rear pulley bolt with impact gun and14mm socket attachment.

v. Set bolt aside.

vi. Remove the front and rear pulley

simultaneously (belt will come out with the

pulleys).

vii. Wipe all surfaces of pulleys and CVT with

rag or paper towels to remove any dirt or

debris.

NOTICE

Small hardware (e.g. bolts, washers,

screws) may fall from front pulley, upon

removal of pulley. Collect small hardware

and set aside for reassembly, later.

NOTICE


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Step 6: Replace Rear Pulley and Belt

i. Turn rear pulley upside down.

ii. Grip and hold down spring-loaded plate.

iii. Hold spring-loaded plate with one hand.

iv. While holding down spring-loaded plate,grab

belt with other hand and loop belt around theexposed area, located above the spring-loaded

plate.

v. Replace rear pulley and belt into CVT case.


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Step 7: Reassemble Front Pulley, if necessary**As previously mentioned, small hardware may fall

from front pulley upon removal. If the hardware fellfrom the pulley, follow the guide below to

reassemble. If the pulley remained intact, skip ahead

to step 8.

Front Pulley Assembly:Parts in diagram (to the left) are ordered from base

to top of front pulley.

(a)Base

(b)PegsFit into the matching crevices of the base.

(c)

U-shaped WashersFit into the u-shaped crevices located on the

edge of the plate.

(d)Plate

Fits (w/u-shaped washers) on top of base

level. Must be flipped from position pictured.

(e)Shaft

Fits into hole of plate and base.

(f)

Pulley FaceFits on top of shaft.

(g)WasherFits on top of pulley face.

Step 8: Replace Front Pulley into CVT Case

i. Face front pulley with pulley face facing

toward you.

ii. Loop left side of belt around front pulley.

iii. Push pulley onto spoke located on the leftside of the CVT case.


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Tapthe impact gun trigger when

removing bolts. Holding the impact gun

trigger will cause damage to bolts and

other nearby components.

Step 9: Attach Front and Rear Pulley to CVT Case

i. Replace rear pulley bolt with impact gun and 14mm socket attachment.

ii. Replace front pulley bolt with impact gun and 17mm socket attachment.

Step 10: Test CVT

i. Turn on scooter.

ii. Observe the front and rear pulleys.

iii. Front pulley should contract, while rear pulley expands.

Step 11: Replace CVT Cover

i. Check CVT cover to ensure the gasket is still

intact.

ii.

Replace CVT cover over CVT.

iii. Tighten all bolts by hand, to reattach CVT

cover.

iv. Tighten all bolts with 8mm socket wrench.

Test bolt replacement using fingers

to turn bolts. If the bolt does not move, the

bolt is set. If the bolt does move, repeat the

trigger tap method of bolt replacement.

NOTICE

Test scooters CVT before replacing

the CVT cover, to prevent any need for

removing CVT cover again. If any

components were improperly replaced,

there is no need to re-open CVT cover.


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Step 12: Replace Air Box and Kick Start Lever

i. Reattach air box.

ii. Screw air box screws with Phillips screwdriver.

iii. Reattach kick start lever.

iv. Tighten kick start bolt with 10mm box end wrench.

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