CVT variator & clutch nuts need to be removed for jobs like replacing belt, changing rollers or plates etc. These usually gets really tight because of regular stress.
CVT(Continuously Variable Transmission) system is one of the most important part of a gearless scooter transmission. This is the part that makes a gearless scooter work without manual gears.
CVT Pulleys – Input driver(driving) pulley & output driven pulley. These parts are also know as clutch assembly & variator assembly.
CVT variator & clutch nuts need to be removed for jobs like replacing belt, changing rollers or plates etc. These usually gets really tight because of regular stress. Not only that, these plates are part of rotating pulley systems. To remove nut on the pulley system we need to hold the plates tightly. Some people jam it with clothes, rope etc. But there is many specialised 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 involves special tools some make use of common items to get the job done.
CVT Holding tools
Universal holder for variator & Clutch.
This is a special tool but in many ways similar to strap wrench; but specially made for this purpose. We can adjust the tightness by rotating its controlling rod. After tightening it around disck, rod can be either held on to a part of scooter itself or on to ground.
Special tool Y – Design.
This one can be used easily for clutch by inserting 2 pins on the end of Y tool on. This can also be used on variater if it have 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 plate on plate.
Although not recommended, good strap wrench can be used to hold 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 tool specifically for your scooter. Following are few videos of such diy tools. This method require some effort and time to make it.
Screwdriver and bolt method.
A big screwdriver or a thing rod can be placed across back wheel and frame of scooter to remove clutch nut. So this method don’t require any special tool. For variater disc also a screwdriver and bolt can be used. Watch following video for demo.
Changing belt without any tools.
If changing belt is your goal, t is totally possible to change variator belt without any tools at all. This can be done by loosening the belt from clutch plate by pulling it outwards and then taking belt out through side of vairater 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.
Starting motor gear teeth is exactly matching with variter wheel teeth. So this self start cog can be used as a stopper for variater disk. This cannot be used for clutch pulley system.
CVT Removing tools.
Using impact wrench.
This is one of the easiest and best ways to do it if you have and impact wrench. You can just use it to remove nut even without any holding tool.
Using 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.
This one is also not recommended but you can try adjustable spanner or pipe wrench to do the job.