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1. Pull CVT cover off and remove the Damper O-ring from Rear Trans Input Shaft assembly and secure it so it
will not be lost (Be careful not to damage the cover gasket on disassembly).
A Low Power Impact gun is required for the following steps. Air or Electric will work.
2. Remove the 17mm Variator Fixed Plate Nut and remove the Fixed Plate from the end of the Splined
Crankshaft end. On 100cc models there will be a 1 mm shim installed between the Fixed Plate and the
Variator Sliding Collar. (The Fixed Plate is the plate with cooling fins on the outside of the assembly to the
front of the engine.)
3. Remove the Drive Belt from the Variator Pulley and the Rear Drive Pulley. (Drive Pulley is the large rear
pulley)
4. Remove the 24mm nut on the rear Drive Pulley/Clutch Assembly and remove the Clutch Bell and Drive
Pulley assembly’s from the Trans Input Shaft.
5. Remove the Variator Moving Assembly from the Splined Crankshaft and remove the Variator Roller
Weight Set. (There will be 6 Roller Weights in total)
Variator Reassembly
1. Install new Roller Weight Set in the Variator Moving Assembly and reassemble the Variator onto the
Splined Crankshaft end.
2. Remember to account for the 1 mm shim if applicable. (Do Not Install the Fixed Plate on Variator at this
time. It will be installed at the end)
Rear Drive Pulley Assembly
1. Remove the Clutch Nut from the outside of the Drive Pulley/Clutch Assembly. (Be careful to hold down on
the Clutch Carrier when removing the Clutch Nut to avoid damaging the threads on the Drive Pulley
assembly.)
2. Remove the (3) Stall Springs from the Clutch Carrier Shoes and reinstall the new Spring Set if applicable.
(2000 rpm springs are all that are generally used. Other values are available for specific applications i.e.
lighter hit on the clutch for timid riders.)
3. Remove the Drive Spring from the Drive Pulley assembly and install the required spring according to the
required stage of performance to be achieved.
4. Reinstall the Clutch carrier onto the Drive Pulley assembly and secure the nut with a 39mm socket and a
Impact gun using a low setting. (Do not over tighten the nut).
You can also place the assembly in a vice and secure the nut with a large 15” Crescent Wrench, be careful not
to damage the belt pulley assembly when using this technique.
Reassembly
1. Reinstall the rear Drive Pulley assembly and the Clutch Bell onto the Trans Input shaft and install the
24mm nut on the shaft. Secure the 24mm nut with an Impact Gun using the low setting. (1 quick hit is all
it takes.)
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