Tranny service with Dr Pulley and Fuzzy Washer
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Veni, Vidi, Posti
RIP: MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5278
Location: Austin, TX
Fri Aug 24, 2012 6:16 am quote
I needed to do my service so I decided to an all rolled into one pictorial walkthrough since I promised the folks with fuzzy washers I'd do a tutorial.

Step one is remove the airbox. This is strictly necessary as one friggin screw on the CVT cover is shrouded. It's a good idea anyway since you should check your air filter and clean it. I'm not going to do detailed pictures of this - 8 or 9 screws and it pops off. I WILL say the best tip I can give here is take a file or grinder and take the sharp point off the screws. This will make it MUCH easier to get back on. Seriously - otherwise getting that darned airbox back on will be the hardest thing about the procedure. Thank PonyDrvr for that tip.

First remove the 4 philips screws holding the plastic CVT cover on. One you must access through a hole in the black plastic part of the cover. Go ahead and remove the dust cover from the driven pulley.



Now you're down to the actual CVT/transmission cover. Remove 7x8mm outer bolts and the 4x10mm "center" bolts. Note the two dead center 10mm bolts are longer than the other two bolts. Hold on - you're not there yet so don't try to remove the cover.



You need to remove the driven pulley 21mm nut at this point. Do NOT use anything other than a 6 sided socket on any of the big nuts.
This is how I do it that doesn't involve wedging anything into the rear wheel. Simply get a 1/2" breaker bar with the 21mm impact socket, put the parking brake on and reach up with your left hand and squeeze the rear brake hard. Use your right arm to break the nut loose. It's not hard at all. BTW - a pair of scrub pants are THE way to go working on your bike in the heat. Cool, roomy, wash clean well and they keep the skeeters off.



Here's how the nut and two washers come off. Note the smallest washer is innermost against the CVT cover bearing. It's extremely important you put these back in this order when reassembling. Note also there is another thicker washer inside when the cover is removed - mine is gold colored. Go ahead and put it with the rest.




This is the Buzetti tool that you need to remove the variator. Folks have made their own but they must be cheaper than I am. Note the two tangs on the center round section - they engage with the two slots on the outer variator half.



This is the Buzetti tool mounted. Note the tangs are engaged with the tangs. You will need to rotate the variator until the proper outer cover bolt holes align. Just use the belt to pull it along easy. The two bolts just need to be snug. Note that I wrote the torque on the tool so I don't have to look it up.



Use your breaker bar with a 27mm impact socket to take the nut off and remove the outer half of the variator. This one requires a little grunting. Note there are two washers under the nut and the outside one is thicker. (thanks for catching that Dirt! )



Here we have the outer cover removed and you can see where the fuzzy washer goes with the stock washer. Order is not important.



Move the belt aside and carefully slide out the inner variator. Reach around the back and hold the sliding plate in place so the rollers and such do not fall out. There is a cylindrical bushing that will come out also, remove and put back on the shaft to protect it.
This shows the Dr Pulley sliders in their proper orientation - there is a groove that should be facing up. Note the smudges are not wear so much as just belt crap that gets rubbed onto the face - they clean right up. These sliders have about 18,000 miles on them. Note how the "shoes" on the inner sliding plate ride on rails cast into the variator. It is important that these not bind so get an old toothbrush and some hot soapy water and scrub all the crap out. The shoes shown are stock and I replaced with Dr Pulley shoes that I had to file the sides a bit so they would seat all the way down on the sliding plate.



Now slide the clutch off, remove the old belt, remove the clutch housing bell and examine. Mine finally showed some glazing/blueing which means it was slipping a bit. If you have a machine shop you might consider having them remove the glazing - a lathe gives a much better new surface. I'm broke so I opted to use a few sheets of sandpaper and lots of elbow grease to remove the glaze. If you opt for sandpaper do NOT sand so as to leave the scratches going in the direction of rotation, make them a "crosshatch" pattern to offer resistance to the pads. Speaking of the pads - they were also glazed so I sanded them to remove it also. Note at the leading edge of the pads there is a worn step. This can cause abrupt transitions so smooth it to more of a gradual ramp. These pads are 24,000 miles so you can see they wear slowly - you aren't going to remove excessive material sanding them. the second picture shows them after deglazing and cleaning up.




Reassemble the inner variator making darn sure the Dr Pulley sliders are in place properly. Insert the inner cover making sure the plate does not bind and can slide freely.



Put a light coat of wheel bearing grease on the splines and wear points of the shafts. We're talking a VERY light coat - we don't want grease flying around inside. On the left you can see the variator bushing - give it a light coat also then remove and place on a rag to keep it from getting dirt. Make sure the rear-most tapered washer is still in place with the bevel facing outward.



At this point you're ready to reassemble everything. Make sure the faces of the two pulleys do not have any oil or grease on them - friction is your friend.
To replace the belt properly and get the clearances to reassemble everything, the belt needs to be seated deep into the clutch. Some folks use a screwdriver to wedge the pulley halves apart. I simply squeeze them apart using the palms of my hand against the clutch bell. The first photo shows my grip, the second shows how the belt drops in when you open the halves. The belt needs to be as deep in the clutch pulley as you can manage but as long as it's below the edge you should be ok.




Slide the clutch all the way back - this is how things should look at this point.



Install the inner variator being VERY careful to hold the sliding plate to prevent movement. I'm serious - if it slips, pull it back out and make sure the sliders have not shifted. If even one shifts the variator will have a rough action - ask me how I know.
When the variator is all the way back, insert the bushing, then the fuzzy washer and stock washer.



Place the outer variator half on, the two washers in the proper order and the nut. Note the picture has teh washers backwards - the fat dark washer is outside. Slowly tighten the nut by hand adjusting the belt until it is a tight as you can get it and the belt is loose. You cannot proceed if the belt is pinched between the pulley halves - it MUST be free. Put the Buzzetti tool back on as previously described and torque to the proper amount which in English units is 118-129 ft/lbs. Remove the Buzetti tool when finished.



At this point reassembly is a reverse of taking it apart.
Make sure the inner washer is against the clutch bell and replace the outer cover. I use the center 4x 10mm bolts to loosely hold the cover in place. Replace the washers - the small one against the cover bearing! Using the same brake holding method used to loosen, torque the driven pulley 21mm nut to 68-74 ft/lbs. Tighten the 10mm bolts using an "X" pattern to ensure even torque. You can look up the exact torque but I just make sure they are tight. Put all the 8mm nuts back and tighten in an "X" pattern starting from the middle. Tighten a little more than snug but not excessive - these don't need a lot of grunt. Replace outer plastic cover and 4 screws.
replace airbox with clean filter. A magnetic screwdriver is your friend with these screws.
Done!

Last edited by BubbaJon on Fri Aug 24, 2012 9:52 am; edited 3 times in total
Molto Verboso
MP3 500 08
Joined: 08 Aug 2009
Posts: 1560
Location: Toms River area, New Jersey
Fri Aug 24, 2012 6:24 am quote
Great job !
Moderatus Rana
MP3 250 (sold) MP3 500 (current)
Joined: 11 Jul 2008
Posts: 21456
Location: Palatka, Florida
Fri Aug 24, 2012 6:31 am quote
Great pics and write up. Shoulda made a wiki out of it. Gonna update the main 400 and 500 wiki pages with a link to this.
Addicted
MP3 500, Lambretta GP TS1 225
Joined: 16 May 2011
Posts: 620
Location: Toronto, Ont
Fri Aug 24, 2012 6:32 am quote
Great video and am (not) looking forward to doing this within the next month. It really is something that I need to do as I like doing long distance and hey, you never know.


Cheers,
Tross
Veni, Vidi, Posti
RIP: MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5278
Location: Austin, TX
Fri Aug 24, 2012 6:38 am quote
stickyfrog wrote:
Great pics and write up. Shoulda made a wiki out of it. Gonna update the main 400 and 500 wiki pages with a link to this.
I'm going to make it a PDF folks can download and print or slap on a iPad if they need.
Moderatus Rana
MP3 250 (sold) MP3 500 (current)
Joined: 11 Jul 2008
Posts: 21456
Location: Palatka, Florida
Fri Aug 24, 2012 6:53 am quote
Great idea. In the meantime I added the links.
Hooked
MP3 250
Joined: 15 Sep 2010
Posts: 333
Location: Toronto
Fri Aug 24, 2012 7:09 am quote
Awesome tutorial - Thanks!

Addicted
MP3 500
Joined: 10 Apr 2011
Posts: 857
Location: Plano, Texas
Fri Aug 24, 2012 7:41 am quote
Thank you so much!!!
Member
Gilera Fuoco
Joined: 06 May 2012
Posts: 14
Location: Göteborg Sweden
Fri Aug 24, 2012 7:52 am quote
Great tutorial. In addition, I usually take the compressor to blow out dust, while the unit is split open. Best done outdoors, since the dust is likely not very healthy.

Some people mentions that the belt has a preferred direction indicated by an arrow. Might be worth commenting here as well. I'm waiting for the moment to check that I actually did this during my recent belt change - there is 50/50 chance I didn't. I'm not sure how important that is, ...
Veni, Vidi, Posti
RIP: MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5278
Location: Austin, TX
Fri Aug 24, 2012 10:18 am quote
Here is the PDF version
Here is the PDF version for use on an iPad or something.

CVT Dr Pulley and Fuzzy service.pdf
 Description:

Download
 Filename:  CVT Dr Pulley and Fuzzy service.pdf
 Filesize:  300.26 KB

Molto Verboso
2007 Piaggio MP3 250 (sold) and 2009 MP3 400
Joined: 30 Jun 2010
Posts: 1842
Location: Floyds Knobs IN
Fri Aug 24, 2012 10:21 am quote
I thought this was a totally different discussion just by reading the title.
i thought it was something to do with a sex change operation....

Molto Verboso
2012 BV 350, 2013 BMW C650 GT, 2015 Indian Chieftain
Joined: 20 Feb 2009
Posts: 1895
Location: Brentwood, TN
Fri Aug 24, 2012 10:27 am quote
Holly - you get a Like! Well played.
Ossessionato
MP3 500 - GTV250
Joined: 07 Jul 2010
Posts: 2968
Location: Near Pittsburgh
Fri Aug 24, 2012 10:29 am quote
hollybry wrote:
I thought this was a totally different discussion just by reading the title.
i thought it was something to do with a sex change operation....

What? "Dr Pulley Doin' Fanny Service and Washin' Fuzzys"?

Wouldja run out and get a helmet and goggles for your new pet spider?
Moderatus Rana
MP3 250 (sold) MP3 500 (current)
Joined: 11 Jul 2008
Posts: 21456
Location: Palatka, Florida
Fri Aug 24, 2012 11:29 am quote
Ha Holly you perv.



Here is a little friend for you.

Enthusiast
Vespa PX 200
Joined: 22 Jul 2010
Posts: 58
Location: UK
Fri Aug 24, 2012 11:35 am quote


Last edited by peartree on Fri Sep 06, 2013 1:58 am; edited 1 time in total
Molto Verboso
2007 Piaggio MP3 250 (sold) and 2009 MP3 400
Joined: 30 Jun 2010
Posts: 1842
Location: Floyds Knobs IN
Fri Aug 24, 2012 11:43 am quote
What?
are you telling me I am the ONLY one that thought of that?
You better stop teasing me with spiders Sticky, or there will be a lump of coal in your stocking this year!
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
Fri Aug 24, 2012 4:12 pm quote
Great job BubbaJon. Thanks.
Ossessionato
2009 MP3-500 aka Red Dog 2007 Vespa 250ie
Joined: 16 Oct 2009
Posts: 2111
Location: Southern Oregon Coast
Sat Sep 01, 2012 1:23 pm quote
Thanks Jon, I guess this means I have to do the belt & fuzzy washer soon; been procrastinating for a year now. Good job on the procedure.

LL75
Ossessionato
MP3 500 - GTV250
Joined: 07 Jul 2010
Posts: 2968
Location: Near Pittsburgh
Thu Sep 06, 2012 6:05 pm quote
Wait a minute!! I thought that picture was backwards. You mean the extra washer goes in the variator and not in the clutch ?
Addicted
MP3 500 (no - longer); 2008 Victory Vision (gone), 2012 Goldwing (gone), 2019 Wee-Strom
Joined: 10 Jan 2009
Posts: 856
Location: Alpharetta, GA
Thu Sep 06, 2012 6:24 pm quote
Great tutorial and nice timing. I need to replace the belt in the next week or so to get ready for the fall gathering. It has been long enough since I last did it, the tutorial was a good refresher.
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 21402
Location: Harriman, Tennessee, Tn
Thu Sep 06, 2012 7:36 pm quote
YaYaDave wrote:
Wait a minute!! I thought that picture was backwards. You mean the extra washer goes in the variator and not in the clutch ?
say you didn't do that.
Hooked
2009 MP3 400ie
Joined: 19 Apr 2008
Posts: 155
Location: Centrally Inaccessible, PA
Fri Sep 07, 2012 3:52 am quote
Beautiful job, and a lasting contribution to the community!
The time and effort you put into achieving clarity on this will be much appreciated.
Thanks,
Michael
mplkn
Ossessionato
2016 MP3/500 Sport ABS, 2009 MP3/250, 2012 GTS Super 300ie
Joined: 08 Jul 2011
Posts: 4227
Location: Marietta, GA
Fri Sep 07, 2012 4:19 am quote
Well Done !

I was comparing to my MP3/250, and it looks to be very similar.

Keith,
Marietta, GA.
Enthusiast
2008 mp3 500, 2013 Suzuki VStrom 650
Joined: 09 Oct 2009
Posts: 58
Location: New Jersey
Fri Sep 07, 2012 5:28 am quote
Thank you for the time in posting this detailed tutorial. Will come in very handy on my next belt replacement...which is soon. Should have no problem following the step by step procedure except for the fuzzy washers (don't have one) and will be wearing green scrubs!
Veni, Vidi, Posti
RIP: MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5278
Location: Austin, TX
Fri Sep 07, 2012 8:09 am quote
Botcheck wrote:
except for the fuzzy washers (don't have one) and will be wearing green scrubs!
You don't know what you're missing
Ossessionato
MP3 500 - GTV250
Joined: 07 Jul 2010
Posts: 2968
Location: Near Pittsburgh
Fri Sep 07, 2012 10:09 am quote
old as dirt wrote:
YaYaDave wrote:
Wait a minute!! I thought that picture was backwards. You mean the extra washer goes in the variator and not in the clutch ?
say you didn't do that.
Well, I thunk it, but I didn't do it.
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 21402
Location: Harriman, Tennessee, Tn
Fri Sep 07, 2012 1:57 pm quote
YaYaDave wrote:
old as dirt wrote:
YaYaDave wrote:
Wait a minute!! I thought that picture was backwards. You mean the extra washer goes in the variator and not in the clutch ?
say you didn't do that.
Well, I thunk it, but I didn't do it.
glad you didn't
Enthusiast
Piaggio MP3 500
Joined: 01 Jun 2012
Posts: 68
Location: Cerritos, CA
Mon Sep 10, 2012 1:50 pm quote
Hey BubbaJon,

Where did you get your Buzzetti holding tool?
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 21402
Location: Harriman, Tennessee, Tn
Mon Sep 10, 2012 2:38 pm quote
DoeBoy71 wrote:
Hey BubbaJon,

Where did you get your Buzzetti holding tool?
the only dealer I know that carries them is scooterwest in san diego
Enthusiast
Piaggio MP3 500
Joined: 01 Jun 2012
Posts: 68
Location: Cerritos, CA
Mon Sep 10, 2012 3:13 pm quote
Found it.

Thanks!
Molto Verboso
MP3 500
Joined: 20 Apr 2008
Posts: 1293
Location: Utah
Sun Sep 30, 2012 3:31 pm quote
If you do not apply a thin coat of grease to the clutch shaft of the outer bearing it will in time seize tight with rust. Making the removal of the transmission cover a 2-person job. You can spend all day reverse tapping the cover and get nowhere. However synchronize with one tapping with a brass flat face punch on the clutch shaft (Place the retaining nut backwards & flush, providing a larger striking area) while the other pulls on the cover. Grease is your friend just do not over do it.
Veni, Vidi, Posti
Neutrino MP3 492.7 AK, 2013 Moto Guzzi Norge
Joined: 29 Mar 2008
Posts: 21402
Location: Harriman, Tennessee, Tn
Sun Sep 30, 2012 3:44 pm quote
Maynard Schweigert wrote:
If you do not apply a thin coat of grease to the clutch shaft of the outer bearing it will in time seize tight with rust. Making the removal of the transmission cover a 2-person job. You can spend all day reverse tapping the cover and get nowhere. However synchronize with one tapping with a brass flat face punch on the clutch shaft (Place the retaining nut backwards & flush, providing a larger striking area) while the other pulls on the cover. Grease is your friend just do not over do it.
here is your problem. your not riding it enough. riding it with enough miles to take the cover off every 3,000 miles for an inspection. now if that takes you a couple years to do it, your not riding it enough. You should do this at least 2x's a year as a minimum. it won't have time to rust if you keep to this shedule.
Veni, Vidi, Posti
RIP: MP3 500 - Brutto Moto
Joined: 10 Jun 2008
Posts: 5278
Location: Austin, TX
Sun Sep 30, 2012 5:03 pm quote
Maynard Schweigert wrote:
If you do not apply a thin coat of grease to the clutch shaft of the outer bearing it will in time seize tight with rust. Making the removal of the transmission cover a 2-person job. You can spend all day reverse tapping the cover and get nowhere. However synchronize with one tapping with a brass flat face punch on the clutch shaft (Place the retaining nut backwards & flush, providing a larger striking area) while the other pulls on the cover. Grease is your friend just do not over do it.
You do see where I put that step with pics in the procedure - right? Front & back shafts...
Molto Verboso
MP3 500
Joined: 20 Apr 2008
Posts: 1293
Location: Utah
Sun Sep 30, 2012 5:26 pm quote
old as dirt wrote:
Maynard Schweigert wrote:
If you do not apply a thin coat of grease to the clutch shaft of the outer bearing it will in time seize tight with rust. Making the removal of the transmission cover a 2-person job. You can spend all day reverse tapping the cover and get nowhere. However synchronize with one tapping with a brass flat face punch on the clutch shaft (Place the retaining nut backwards & flush, providing a larger striking area) while the other pulls on the cover. Grease is your friend just do not over do it.
here is your problem. your not riding it enough. riding it with enough miles to take the cover off every 3,000 miles for an inspection. now if that takes you a couple years to do it, your not riding it enough. You should do this at least 2x's a year as a minimum. it won't have time to rust if you keep to this shedule.
So True. I split my transportation among 4-modes, bicycle,SUV,bus & MP3. Winter snow & ice (salted roads) knocks the MP3 and bicycle out of service for 4-5 months.

Another item that should be noted is spline wear on the clutch bell. If the splines appear as small pyramids replace the bell before wear damage occurs on the clutch shaft.$$$labor$$$ Depending on your driving habits and what grease is used. Use the highest % moly grease you can find with 60% as the best.

Splientology

splinesworn.jpeg

Spline.jpeg

Hooked
MP3 500
Joined: 28 Apr 2012
Posts: 129
Location: Toronto
Sun Sep 30, 2012 7:03 pm quote
Thank you for this writeup BBJ!

I followed the instructions and was able to use all your pics to ensure I reassembled everything right.

I got the HiT clutch too from the recent GB, but today, I decided to just do the Fuzzy washer, belt, and Dr. Pulley 17g weights and shoes. I slid the back variator plate with the new shoes against the front half and filed down the high spots on the shoes slightly. Everything fits great, and I'll save the clutch prolly for next yr.

All I can say is that the scoot is now mental from 60 - 100km/h (30 - 60mph)!
Molto Verboso
MP3 500
Joined: 20 Apr 2008
Posts: 1293
Location: Utah
Sun Sep 30, 2012 7:35 pm quote
BubbaJon wrote:
You do see where I put that step with pics in the procedure - right? Front & back shafts...
I applaude your post. I only ment to reinforce the usage of grease, and if you don't as in my case during long periods of down time. Rust can creep in and it will take another set of hands to pop the transmission cover off. "Been there done that" and wishing only to help anyone else.
Hooked
Joined: 11 May 2008
Posts: 206
Location: Roseville, CA
Mon Oct 01, 2012 5:28 am quote
damn fine writeup! I believe even I could follow it!
Hooked
MP3 500
Joined: 28 Apr 2012
Posts: 129
Location: Toronto
Tue Oct 09, 2012 6:39 am quote
so it's ben a couple of weeks since I did the service. a part of me regret not doign the clutch since it'll just be sitting here mocking me in the off-season. last night, I was able to get the scoot to hit over 7000rpm.

this morning, when I went to start 'er up, the transmission light started flashing. no weird sounds, no squeeling or squeaking...no odd smells. after about 10secs of riding out the underground garage, the light went off.

any idea what this could be?
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 37587
Location: Pleasant Hill, CA
Tue Oct 09, 2012 6:58 am quote
What 'transmission light'? If you mean the belt service icon on the digidash, then the reset procedure is in the workshop manual:

500servicereset.jpg

Hooked
MP3 500
Joined: 28 Apr 2012
Posts: 129
Location: Toronto
Tue Oct 09, 2012 7:02 am quote
jimc wrote:
What 'transmission light'? If you mean the belt service icon on the digidash, then the reset procedure is in the workshop manual:
Thank you! I suppose it's just a reminder for belt service? I guess I can safely reset it since I did the belt. =)
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