Scooter repair guidebook

CVT(Continuously Variable Transmission) system is one of the most important parts of a gearless scooter transmission. This is the part that deliver power from engine to back tire without manual gears.

Gearless scooters still have internal gear system but as a user, you don’t have to worry about it anyway.

CVT belt wear out - sign and symptoms.

When scooter refuses to move until it reaches very high rpm, it is one of the main indicator of a worn belt.

Other symptoms

• Too much vibration at idle.
• Scooter struggle to go faster.
• Low speed, low power & always running on high rpm.
• CVT belt slipping.
• Unusual sound from CVT pully.

CVT Pulleys - Input driver(driving) pulley & output-driven pulley. These parts are also known as clutch assembly & variator assembly.

CVT variator & clutch nuts need to be removed for jobs like replacing the belt, changing rollers or plates, etc. These usually get really tight because of regular stress. Not only that, these plates are part of rotating pulley systems. To remove the nut on the pulley system we need to hold the plates tightly. Some people jam it with clothes, rope, etc. But there are many specialized tools for doing this job.

Useful tips: Use different nut on variator & clutch wheels each time for easy removal next time.

Direction - Both nuts on variator and clutch disk are usually similar to other ones(Lefty loosey-righty tighty). So turn anti clockwise direction to remove it.

Following are some different ways to do this job. Some involve special tools some make use of common items to get the job done.

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CVT Holding tools

Universal holder for variator & Clutch.

This is a special tool but in many ways similar to a strap wrench; but specially made for this purpose. We can adjust the tightness by rotating its controlling rod. After tightening it around the disk, the rod can be either held on to a part of the scooter itself or on to the ground.

Special tool Y - Design.

This one can be used easily for a clutch by inserting 2 pins on the end of the Y tool. This can also be used on the variater if it has holes on the disk(some models have holes on the disk for this purpose). But don’t use it on fan-like fins.

Special tool with pins.

Many different versions of these tools are available specially made for specific models. This tool will hold on clutch plate holes. Then it can be placed on the ground for holding the plate in place.

Strap wrench.

Although not recommended, a good strap wrench can be used to hold the CVT system in place.

Special customised tools.

If you have access to a drilling machine & angle grinder(and iron sheet and rods), you can make some tailor-made tools specifically for your scooter. Following are few videos of such DIY tools. This method requires some effort and time to make it.

Screwdriver and bolt method.

A big screwdriver or a thing rod can be placed across the back wheel and frame of the scooter to remove the clutch nut. So this method doesn’t require any special tool. For the variator disc also, a screwdriver and bolt can be used. Watch the following video for a demo.

Changing belt without any tools.

If changing the belt is your goal, t is totally possible to change the variator belt without any tools at all.

This can be done by loosening the belt from the clutch plate by pulling it outwards and then taking the belt out through the side of the vairator disk.

This method will not work on all scooters though. Following is a demo video, on how to do it.

Removing variator nut without any tools - using self start gear cog.

The ‘starting motor gear’ teeth is exactly matching with variator wheel teeth. So this self-start cog can be used as a stopper for the variator disk. This cannot be used for a clutch pulley system.

CVT Removing tools.

Using impact wrench.

This is one of the easiest and best ways to do it if you have an impact wrench. You can just use it to remove the nut even without any holding tool.

Regular spanner.

Using a regular spanner will be a challenge since you are trying to loosen a very tight nut. Chances of slipping, nut getting damaged are high. Sometimes it is not even possible to use a regular spanner

L shape spanner.

This is the best option if you don’t have any fancy tools available. A long L spanner is or a spanner with an extending pipe inserted on top will do the job easily.

Adjustable spanner.

This one is also not recommended but you can try an adjustable spanner or pipe wrench to do the job.