Changing Variator Weights

I changed my variator weights today. This really works. The difference in acceleration is noticeable. You actually can feel a little push back in the seat. For under $50 I think this is the best performance mod you can do. RPMS drop to pretty much stock once you are cruising.

First it seems 13 grams is ideal and stock is 15. I had four 10 gram weights so I put in 4 10's and 4 15's for an average of 12.5. It works.

Took me 3 1/2 hours including putting on the air filter cover first then realising the front variator cover had to go on first, and having an airbox screw take a dive into the bowels of the scooter, and a brief pizza break.

This is not a job for a real beginner. Here are some tools you will really find handy:

- a hand impact screwdriver - get one at Sears for $30, there are some Phillips head screws that CANNOT be removed by hand

- a magnetic retriever - for the screw that took a dive

- an impact wrench

- a 3/8" drive torque wrench

Here is how I did it including a few tricky (at least for me) parts:

- first you are going to remove a lot of fasteners and you need to keep them organized. I use plastic yogurt containers but don't just mix them all up

- I have some old white sheets to use in the garage, make sure they are clean, this allows you to put the variator parts down on a clean surface where you can see them and they won't get dirty

- first remove the lower colored body strip

- then remove the plastic covers over the variator, and the air filter cover.
I needed the impact screwdriver to remove the Phillips head screws
of the large plastic variator cover.

- next remove the aluminum variator cover. Ease it off gently as it has
bearings for the primary and secondary sheaves

- remove the variator nut with an impact wrench

- carefully remove the variator, take it apart and swap your weights

- replace the variator - I got stuck here - the belt prevents the variator
from going on far enough to start the nut. The key is to pry to two
pulley halves of the clutch (secondary sheave) apart some - do this
with a piece of wood so you don't scratch the aluminum - then the
variator slips right on.

- tighten the variator nut with the impact wrench. If you do not
have access to an impact wrench you can make a tool that holds
the variator immobile like the Yamaha shop tool. The Reflex
Owners Group board has a link on how to make one. Sorry, I don't
have the link.

- put all the covers on with their bazillion fasteners

- if you get it all together without having a fastener left over or losing
one in the bowels of the beast congratulations (magnetic retrievers
are wonderful)

- take a break and then enjoy the real acceleration difference you
can feel for less than $50.