J COSTA INSTALL - MP3 400 - with pictures
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Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Mon Jun 15, 2009 1:48 pm quote
You will need:


- Set of standard screwdrivers
- Variator holding tool - http://www.modernvespa.com/forum/topic47278
- Torque wrench
- Impact wrench - not necessary but it will make your life easier.
- 27mm & 21mm 6 sided sockets for your torque wrench.
- Something to lock the rear wheel with - wooden wedge


DSC01157.JPG
Start with taking 4 black screws which hold transmission plastic cover out..

DSC01159.JPG
You gonna have to remove air filter cover for the transmission plastic cover to come off.. It should be 9 screws

DSC01158.JPG
Take the plastic round cover off using screw driver...

DSC01160.JPG
Finally the plastic cover is coming off..

DSC01162.JPG
Undo the driven pulley nut using either impact wrench or any other wrench.
21mm 6 sided socket - I used 1/2'' drive and it worked great.

DSC01161.JPG
Now the aluminum transmission cover screws, 7 smaller ones and 4 bigger ones..

DSC01171.JPG
Transmission cover off..

DSC01172.JPG
Attach variator holding tool. This one is from company called Buzzetti. More info here http://www.modernvespa.com/forum/topic47278

DSC01173.JPG
Undo drive pulley nut. Best for this is an impact wrench as it is very tight. 27mm 6 sided socket - I used 1/2'' drive and it worked great.

DSC01175.JPG
Remember which washer goes where. The bigger one no. 1 first than smaller no.2

DSC01176.JPG
Behind outer variator pulley you will find another washer..

DSC01179.JPG
Check the driving belt... this one looks OK after 3333 km :)

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Variator with OEM rollers

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Bushing and the variator housing with "shoes"

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OEM variator and J COSTA

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Housings

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OEM variator

DSC01190.JPG
J COSTA

DSC01197.JPG
Notice that behind the variator is "another" washer. Just leave that on..

DSC01196.JPG
Its ON!



Last edited by joe bulva on Mon Jun 15, 2009 2:05 pm; edited 1 time in total
Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Mon Jun 15, 2009 1:53 pm quote
.......................................

dsc01198_999.jpeg
Put it all back on in reverse order BE VERY CAREFUL WITH ORDER OF WASHERS !!!! Torque the drive pulley nut - torque 160 - 175 Nm.
Make sure that the drive belt is down in between the clutch pulley halves (It is not like that in the picture!) otherwise you

dsc01169_557.jpeg
Put no.1 washer on, then the aluminum transmission cover and then washer 2 and 3. Just to confirm no. 1 washer goes UNDER transmission cover!

dsc01199_171.jpeg
Torque the Driven pulley nut - torque 92 - 100 Nm. You need to lock the rear wheel.I used the handle of the big axe + holding the rear brake + parking brake



Last edited by joe bulva on Tue Jun 16, 2009 4:36 am; edited 9 times in total
Enthusiast
MP3 400, 250GTS Yellow(sold)
Joined: 14 Mar 2008
Posts: 57
Location: East Bay, No Cal
Mon Jun 15, 2009 3:05 pm quote
EXCELLENT Write up. Will print and save it when I do mine.
Addicted
His - 2009 Kawasaki Vulcan 900 Classic LT, Hers - 2008 MP3 250
Joined: 17 Jun 2008
Posts: 541
Location: Modesto, CA
Mon Jun 15, 2009 3:09 pm quote
No immediate plans to change the variator on my wife's 250, but, man, well done! I've book marked this thread.
Ossessionato
2009 MP3 400
Joined: 27 Jul 2008
Posts: 2005
Location: Saratoga, N.Y.
Mon Jun 15, 2009 3:13 pm quote
Cool, thanks for that, Joe Bulva.

Haven't found a source for that Buzzetti holding tool in the U.S.A.
Hooked
2009 Piaggio MP3 400ie
Joined: 20 Aug 2008
Posts: 349
Location: Austin TX
Mon Jun 15, 2009 5:47 pm quote
Excellent write up!
Just wanted to extend a big, "PROPS!" to a most excellent write-up. Very well done.

Cheers!

chris
Molto Verboso
MP3 500, Honda PCX
Joined: 20 Jul 2008
Posts: 1123
Location: Dallas, TX
Mon Jun 15, 2009 7:07 pm quote
Very informative and well done. I already paid to get mine installed and would say it was money well spent. I wish I had your mechanical ability.
Ossessionato
R.I.P. ----K.I.T.T.500, Agent Orange (400)
Joined: 04 Jul 2008
Posts: 2670
Location: Rockford, IL
Mon Jun 15, 2009 7:32 pm quote
Awesome write up!!! I have been asking and pleading for just this sort of step by step write up for awhile...Great job! I'm gonna save this and definitely see if I can use it to install a JCosta to my 500 in the future!!
Hooked
2009 MP3 500
Joined: 08 May 2009
Posts: 122
Location: Medford, Oregon
Mon Jun 15, 2009 7:57 pm quote
Excellent, Joe. Clear large pics and step by step. Now, put together a workshop manual with pics like these and I'll buy a copy!.
Hooked
Piaggio MP3 400
Joined: 08 Aug 2008
Posts: 383
Location: Concord, CA
Mon Jun 15, 2009 9:28 pm quote
I will never attempt to do this myself but wow. Looking at these pictures sure helps me understand the mechanics to some degree some part of what makes my scoot go. This is really fascinating. Bloody brilliant.

Dale
Member
Joined: 07 Jul 2006
Posts: 49
Location: venice, ca
Mon Jun 15, 2009 9:45 pm quote
Thanks!
Enthusiast
2009 MP3 400
Joined: 18 Jan 2009
Posts: 84
Location: Thunder Bay, Canada
Tue Jun 16, 2009 12:36 am quote
Very Well Documented!!!! Wish I could buy you a Pint or two..... Looks like I know what I'm getting next.....
Enthusiast
Fuoco 500
Joined: 29 Mar 2009
Posts: 84
Location: Australia
Tue Jun 16, 2009 2:28 am quote
I'll add to the many thanks. Nothing like good photos and step by step instructions.
Lurker
Piaggio/Derbi 250ie
Joined: 15 Jun 2009
Posts: 1
Location: Berlin, Germany
Tue Jun 16, 2009 2:37 am quote
Thanks a bunch - excellent job, Joe! I was waiting for something like this, and I just ordered my Costa ... yes, I CAN!
Veni, Vidi, Posti
. . 2008 Blue MP3 400. . di Peluria Orso .... 1993 Kawasaki Vulcan 500 ....... 2013 Honda NC700XD; 2017 Versys X300
Joined: 02 Jun 2008
Posts: 6153
Location: Milledgeville, GA
Tue Jun 16, 2009 2:46 am quote
Awesome tutorial. I had just recently taken the plunge to get inside my 250. Then looked at my new 400 from the outside and was wondering how to get the cover off as it is different.

Do not see in the pictures anywhere to use a holding tool for the clutch nut. Holding the rear wheel is probably fine, but the tool for the 250 is low cost.

Has anyone found a source that has the variator tool in stock for delivery to U.S.?
Hooked
Fuoco 500ie SOLD
Joined: 08 Mar 2009
Posts: 234
Location: North West, England
Tue Jun 16, 2009 3:18 am quote
Good write up, but can I add a couple of points.

When undoing the clutch nut use an offset ring spanner on the nut. The shaft has an hexagon on it to allow the use of a socket and wrench to hold the shaft still.

For tightening the clutch nut I found with the weight of the bike on the back wheel and parking brake applied that was enough to be able to torque the nut up with a torque wrench.

When tightening the variator nut, make sure that the drive belt is down in between the clutch pulley halves (doesn't look like it is in the picture) otherwise you risk tightening the outer pulley half against the belt. Then when the belt moves up the ramps the nut is not as tight as you thought. Resulting in the variator nut then working loose.
Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Tue Jun 16, 2009 4:12 am quote
Soeley wrote:
When tightening the variator nut, make sure that the drive belt is down in between the clutch pulley halves (doesn't look like it is in the picture) otherwise you risk tightening the outer pulley half against the belt. Then when the belt moves up the ramps the nut is not as tight as you thought. Resulting in the variator nut then working loose.
Very good point!
I've put your note under that picture.

Otherwise thank you for the praising comments guys. This forum helped me many times so why not pay some of it back
Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Tue Jun 16, 2009 4:41 am quote
joe bulva wrote:
Soeley wrote:
When tightening the variator nut, make sure that the drive belt is down in between the clutch pulley halves (doesn't look like it is in the picture) otherwise you risk tightening the outer pulley half against the belt. Then when the belt moves up the ramps the nut is not as tight as you thought. Resulting in the variator nut then working loose.
Very good point!
I've put your note under that picture.
There is s bug on this forum which doesn't let me to update the note under the picture in full. I can add it and preview it fine, but once I submit it's just not there. I've tried everything including re-adding the whole post and using a different browser. Is there any admin arround please?
Molto Verboso
She's an I-talian $$-burning machine
Joined: 12 May 2008
Posts: 1859
Location: America, The Beautiful
Tue Jun 16, 2009 5:11 pm quote
Excellent DIY post
Great photo details! Good job! Nomination for the Technical Library!!
(*We need to make that variator tool more available... Unless, Jettin' Industries could make us one??)
Just one question, is the ax handle jammed up against the bottom of the transmission cover?
Also, are you going to write about your impressions of the scooter w/ the J Costa?
Hooked
MP3 400-THMP3R
Joined: 07 Dec 2007
Posts: 478
Location: Atlanta
Tue Jun 16, 2009 6:33 pm quote
Can "we" get this put into the MP3 Wiki (which I will point out has absolutely nothing in it). This would make a great first article.
Hooked
2009 MP3-500 Black
Joined: 07 Jun 2008
Posts: 366
Location: Amarillo, TX
Tue Jun 16, 2009 8:11 pm quote
Glow Guy wrote:
Can "we" get this put into the MP3 Wiki (which I will point out has absolutely nothing in it). This would make a great first article.
There is a post similar to this here http://www.modernvespa.com/forum/topic36495?sid=c1631ecfe693206079c3ff5541139b0f posted on this wiki http://mp3scooter.wetpaint.com/
Molto Verboso
She's an I-talian $$-burning machine
Joined: 12 May 2008
Posts: 1859
Location: America, The Beautiful
Tue Jun 16, 2009 8:34 pm quote
Attention moderators: this thread should be included in the Technical Library. That's where it belongs.
Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Wed Jun 17, 2009 12:54 am quote
Re: Excellent DIY post
sushiman007 wrote:
Great photo details! Good job! Nomination for the Technical Library!!
(*We need to make that variator tool more available... Unless, Jettin' Industries could make us one??)
Just one question, is the ax handle jammed up against the bottom of the transmission cover?
Also, are you going to write about your impressions of the scooter w/ the J Costa?
The axe handle is jammed against the bottom of the transmission itself, not the black cover (if I recall). Also with parking + rear brake applied it didn't put as much strain on it (that was my feeling anyway).

You can find my impressions with J COSTA here http://www.modernvespa.com/forum/topic47908

My opinion is that it performs differently on 400 & 500. Someone already pointed out that lighter weights would be more suitable for 400 but as far as I know J COSTA ships only one standard set of weights for both 400 & 500.
Next thing for me would be to experiment with Dr. Pulley HiT clutch + Sliding rollers and see how that performs.
Main thing I am aiming for is fast acceleration from stand still
Molto Verboso
She's an I-talian $$-burning machine
Joined: 12 May 2008
Posts: 1859
Location: America, The Beautiful
Wed Jun 17, 2009 3:47 am quote
Re: Excellent DIY post
joe bulva wrote:
Next thing for me would be to experiment with Dr. Pulley HiT clutch + Sliding rollers and see how that performs.
Main thing I am aiming for is fast acceleration from stand still
Looking forward to that, too.

It's nice to see someone who's technically, as well as financially confident enough to experiment with new products like that, especially in this declining economy.
Enthusiast
2009 MP3 400ie RL
Joined: 20 Feb 2009
Posts: 84
Location: UK
Wed Jun 17, 2009 11:29 am quote
sushiman007 wrote:
It's nice to see someone who's technically, as well as financially confident enough to experiment with new products like that, especially in this declining economy.
It's funny you say that because I was made redundant today. One week notice
Molto Verboso
She's an I-talian $$-burning machine
Joined: 12 May 2008
Posts: 1859
Location: America, The Beautiful
Wed Jun 17, 2009 3:39 pm quote
Sorry, it was in no way intended...
joe bulva wrote:
sushiman007 wrote:
It's nice to see someone who's technically, as well as financially confident enough to experiment with new products like that, especially in this declining economy.
It's funny you say that because I was made redundant today. One week notice
Oops, I am really sorry to hear about your loss of employment. Is that how they call it across the pond-- "made redundant", that's cold! Keep looking, something better will come. You seem like a creative type, a fighter and a survivor (with good humor). In this economy, I guess no one should feel too surprised being laid off, let go, or "made redundant". I go to work everyday accepting the fact that "today could be my last day", seriously.

Cost-cutting has really gone mad all over the place, because it is always easier to do that than to find out why the business is failing (I've been to the chopping block once before so I know; and many times I have been on the other end of the block, so perhaps it's bad karma). I hope you will leave with some sort of benefit package; at least you don't work for British Airways, they're asking employees to work four weeks for free! Oh, man, you don't work for BA, do you, if so, I am really, really sorry?
Ossessionato
2009 MP3 400
Joined: 27 Jul 2008
Posts: 2005
Location: Saratoga, N.Y.
Thu Jun 18, 2009 11:35 am quote
Good news
I wrote Motorsport Scooters (scooterwest.com) a week or so ago asking about the Buzzetti variator holder for the 400/500 Master engine (part #5446) and was told they don't plan to carry it. So I wrote to Buzzetti asking for a U.S. distributor, and they referred me back to Steve @ Motorsport.

Well waddaya know, here's his reply:
Quote:
From: STEVE BAILEY [steve@scooterwest.com]
Sent: Thursday, June 18, 2009 2:35 PM
Subject: Re: Buzzetti tool?

I'm glad this email made it's way to my desk. I'm in the process of
finalizing a Buzzetti order and would love to add the variator tool
you have requested. We should have them in stock in about three weeks.
You can let all your fellow MP3 owners know that we will have them
available soon. Thanks again for your inquiry.

Regards,
Steve
steve@scooterwest.com

MOTORSPORT SCOOTERS
4225 30th Street
San Diego CA 92104 USA
619-280-1718
Fax 619-280-1793
Rejoice!
Molto Verboso
She's an I-talian $$-burning machine
Joined: 12 May 2008
Posts: 1859
Location: America, The Beautiful
Thu Jun 18, 2009 2:02 pm quote
Re: Good news
ramblerdan wrote:
...Well waddaya know, here's his reply:
Quote:
From: STEVE BAILEY [steve@scooterwest.com]
Sent: Thursday, June 18, 2009 2:35 PM
Subject: Re: Buzzetti tool?

...We should have them in stock in about three weeks.
You can let all your fellow MP3 owners know that we will have them
available soon.

Steve
MOTORSPORT SCOOTERS
Rejoice!
Thank you, ramblerdan, for your persistence in getting this tool! You're our hero!

And thanks to Steve @ Motorsport for responding to the needs of its customers!
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 37669
Location: Pleasant Hill, CA
Thu Jun 18, 2009 2:31 pm quote
Re: J COSTA INSTALL - MP3 400 - with pictures
joe bulva wrote:
You will need:
An absolutely excellent description and visual aid. Full marks.

Addendum for those with more long-legged bikes - while you have access to it, check that the idler pulley is spinning freely and without any noise. The bearings in these can fail in various ways leading to hugely increased belt wear. Just spin the pulley with your fingers - anything suspect and get it checked more carefully. Replacement bearings are a standard size (so no OEM part necessarily required) so cheap and easy to replace.
Hooked
Honda Ruckus - MP3 250 - Yamaha Morphous - Honda Elite 250
Joined: 24 May 2008
Posts: 289
Location: Bay Area
Fri Jul 10, 2009 7:46 am quote
Very well done, thank you!
Moderatus Rana
MP3 250 (sold) MP3 500 (current)
Joined: 11 Jul 2008
Posts: 21457
Location: Palatka, Florida
Fri Jul 10, 2009 11:49 am quote
Maybe the best thread I have read on here and that is saying something cause there have been really great ones. Thanks for taking the time to do that!
Veni, Vidi, Posti
. . 2008 Blue MP3 400. . di Peluria Orso .... 1993 Kawasaki Vulcan 500 ....... 2013 Honda NC700XD; 2017 Versys X300
Joined: 02 Jun 2008
Posts: 6153
Location: Milledgeville, GA
Sun Jul 26, 2009 4:15 pm quote
Joe, I printed your post and pictures. I then used them step by step to take my variator off and replace the rollers with Dr Pulley 15 gram sliders. Great tutorial and thank you for making my task easier with good instructions.

Your post is the type help that truely makes MV a great source of information for the MP3.

THANK YOU

PS I will report on the results of the sliders when I have time to use them a bit. Quick test ride before dinner was a good first impression.
Enthusiast
MP3 500
Joined: 25 Jul 2009
Posts: 81
Location: Aurora, OR
Sun Aug 09, 2009 6:38 pm quote
I used these instructions to install the J Costa Variator on my MP3 500 today. It made the installation smoother than the variator itself.

Thank you!

One note.....I only had one washer on the exterior of the aluminum housing (rear nut) instead of two like you show on the 400.
Enthusiast
MP3 400
Joined: 30 Jul 2009
Posts: 84
Location: San Jose, CA.
Tue Aug 18, 2009 12:30 pm quote
Joe Bulva - I was wondering if you might be able to answer a couple of questions concerning the OEM rollers.
1. I notice they sell on-line different sizes for roller weights: 15x2, 16x3, 17x12, etc. Do you know the actual size of the OEM rollers use on the Mp3 400? I like to get the same OEM rollers to replace mine old ones.
2. Where can I purchase these OEm rollers? I can't seem to find them on-line anywhere. The rollers I found are for MP3 250 or MP3 500.
Great illustrations by the way. Thanks for the step-by-step instructions.
Banned
Joined: 24 Apr 2008
Posts: 2919

Tue Aug 18, 2009 1:55 pm quote
DantheMan wrote:
Joe Bulva - I was wondering if you might be able to answer a couple of questions concerning the OEM rollers.
1. I notice they sell on-line different sizes for roller weights: 15x2, 16x3, 17x12, etc. Do you know the actual size of the OEM rollers use on the Mp3 400? I like to get the same OEM rollers to replace mine old ones.
2. Where can I purchase these OEm rollers? I can't seem to find them on-line anywhere. The rollers I found are for MP3 250 or MP3 500.
Great illustrations by the way. Thanks for the step-by-step instructions.
You can only get OEM parts from a dealer, try here for OEM parts.
www.athensscooterco.com

For the aftermarket rolls go here
www.ScooterTrap.com

Wayne B
Ossessionato
2009 MP3 400
Joined: 27 Jul 2008
Posts: 2005
Location: Saratoga, N.Y.
Wed Sep 30, 2009 2:37 pm quote
Just replaced my belt and weights (with Dr. Pulley sliders) today. Used both the horribly translated OEM service manual and Joe Bulva's instructions here. Job went very smoothly. The only head-scratching came when I needed to get the belt seated inside the dishes on the clutch side so there would be enough slack on the variator side.

Thanks again to Joe Bulva for the tutorial.

More notes:

* The M6 screws on the transmission case had 8mm heads; the M8 screws, 10mm. The hex shaft on the clutch side is also 10mm.

* I couldn't find a 20mm offset ("misaligned" as they call it in the manual) wrench for the transmission case (clutch) nut, but 13/16" worked perfectly.

* The variator nut is 27mm, which I also didn't have, but a 1-1/16" six-point socket was a very good fit.

I always wondered why they made oddball SAE sizes like 15/16" and 1-1/16". When would either be better than a 1"? Maybe they did it on purpose to approximate metric sizes? I suspect that metric socket and combination sets typically skip over 20mm because of the wide availability of 13/16". Likewise 19mm being relatively hard to find (here in the U.S., anyway) because it's a match for 3/4".

* Page ENG-3 of the MP3-400 service manual says "Remove the six M6 screws" from the transmission case. That is an error; there are seven screws, just as it says on page ENG-18.

Last edited by ramblerdan on Wed Sep 30, 2009 3:12 pm; edited 1 time in total
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 37669
Location: Pleasant Hill, CA
Wed Sep 30, 2009 2:55 pm quote
ramblerdan wrote:
* Page ENG-3 of the MP3-400 service manual says "Remove the six M6 screws" from the transmission case. That is an error; there are seven screws, just as it says on page ENG-18.
By the time you've done it ten times there'll only be five.
Addicted
Piaggio Mp3250
Joined: 10 Aug 2009
Posts: 605
Location: London
Wed Sep 30, 2009 4:04 pm quote
Give Joe lots of Karma.

if it's any help Joe. I have been running on a third of annual turnover for nearly a year and there are at last real signs of recovery in my industry, fingers crossed knock on wood mind that ladder!

Fay
Molto Verboso
MP3 500, Honda PCX
Joined: 20 Jul 2008
Posts: 1123
Location: Dallas, TX
Thu Oct 01, 2009 11:19 am quote
Excellent post! I printed it as a pdf file and put it away in my Piaggio folder even though the dealer already installed my J Costa. You never know what will come up.
Enthusiast
MP3 500, BMW R1200GS
Joined: 17 Jun 2008
Posts: 68
Location: Coastal North Carolina
Mon Oct 05, 2009 10:45 pm quote
JCosta Tutorial
Brilliant piece. Thank you for the effort.

Does anybody care to advise me with regard to slider weights for my 500 if I even have a choice with the Jcosta. I am after acceleration above all else, so what can I expect?
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