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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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So I didn't like the idea of spending $200 or more on belt replacement tools. One day while at work, I measured the clutch access holes and used the lathe & mill to make a clutch tool.
I was thinking that I could make the tools in a way that someone without access to a lathe and mill could make them.
Yes I Know that a tool can be made with a U bolt. If you knew the distance between the access holes, you would agree that it would take a large U bolt and quite a bit of bending.
First I'm going to show you my clutch tool. Then I'm going to show you how to make a clutch and outer drive pulley tool for less than $15.
Please DON'T reply to this thread until I'm finished(I'll let you know).
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Forum member supplied image with no explanatory text
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Addicted
2015 BV350 2007 GTS(sold) 2003 BV200
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2015 BV350 2007 GTS(sold) 2003 BV200
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UTC quote
I give this a thumbs up.

John
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Hooked
piaggio hexagon
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Location: lincolnshire uk
 
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piaggio hexagon
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UTC quote
Looking good so far. About the only thing I miss about work since I retired Is the access I used to have to all those lovely machine tools and the great guys who operated them.
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
What you need to do the job is: Hacksaw, Drill, file(I have a hand held belt sander), measuring device, 13/64 (#7) drill bit, 17/64 drill bit, 1/4-20 tap, and center punch.
In the pictures are: 3/16 x 1 x 3ft steel bar from Home depot, Lowes or Ace, (2) 1/4 x 3in. bolts, (2) bolts long enough to cut the heads off with one 3/16" longer than the other, (4) 1/4-20 nuts, (2) 1/4-20 bolts with 1/2" working length, (1) 1/4-20 bolt 3/4" working length and (1) nylon 1/4-20 lock nut.
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Forum member supplied image with no explanatory text
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
First cut (4) 3" pieces off the bar. Then cut (1) 6" piece off and you will have 18" left.
Two of the four 3" pieces drill 13/64 hole 1/4" from both ends. Then tap them 1/4-20.
The other two pieces, drill 17/64 hole 1/4" from both ends. That's the end of the bar to the center of the hole.
The 6" bar gets one 1/4-20 tapped hole 3/8" from one end and one 17/64" hole 3/8" from the other end.
The 18" bar gets one 1/4-20 tapped hole 3/8" from one end and one 17/64" hole 5 5/8" from same end.
The two 1/4 x 3 bolts get the heads cut off them and the saw cut smoothed with file.
The smaller bolts get cut off with 1" of the smooth portion exposed on one and 1 3/16" on the other.
Tapped plates
Tapped plates
Plates with 17/64" holes
Plates with 17/64" holes
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
Assembly of the clutch tool.
First screw one 3" headless bolt into each threaded plate.
First screw one 3" headless bolt into each threaded plate.
Put one plate with 17/64" hole over threaded end and screw on nut.
Put one plate with 17/64" hole over threaded end and screw on nut.
Put two half pieces together like so.
Put two half pieces together like so.
Another view.
Another view.
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
I don't have enough pictures for a step by step for the pulley tool.
First install the bolts into the plates all the way and install nuts and tighten them.
When you bolt the plates together, make sure to have the pins the same length before tightening. Tighten the bolt all the way and back it off so there's no play but the 6" plate moves freely.





Now that I'm finished with this post. I'll answer any questions about any missing or unclear information Nerd emoticon
Forum member supplied image with no explanatory text
This is how the pins should line up.
This is how the pins should line up.
⬆️    About 1 month elapsed    ⬇️
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UTC quote
I guess the OCD is kicking in, all hole dimensions are to center line?
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
Not much of an actor. And a 1/4-20 tapped hole is drilled 13/64 not 13/32, oops.

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Piaggio BV350
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Breaknwind,I hope you don't mind but I copied and edited the text with pix as a copy for my own use. Shhh emoticon
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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UTC quote
Be my guest.
I paid $130 for a split beam 20-100 ft.lb. torque wrench and $175 for a 0-30 dial torque wrench. Every little bit of savings helps.
⬆️    About 2 years elapsed    ⬇️
@bean_counter avatar
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2016 BV350 White
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Location: East LA County, CA, USA
 
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@bean_counter avatar
2016 BV350 White
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Posts: 458
Location: East LA County, CA, USA
UTC quote
I was searching on Amazon and eBay with the words variator holding tool and a lot of potential options came up for around $10 to $20. The parts look the similar to the OEM variator holding tool except that they have a locking piece on the side and both of the legs move instead of just one. There are tools that are made for other scooter manufacturers to do the same thing. They have different names for them though. With a bent U-bolt to hold the clutch and a non-EOM variator holding tool I'm looking at less than $20 for what I need. I am going to order one of them, but not until I need to replace my belt and rollers. If anyone has tried one of these on a BV350 let the rest of us know how it went.
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Red Devil SH150i (10,000)
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Red Devil SH150i (10,000)
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Location: Orange Park Florida
UTC quote
bean counter wrote:
I was searching on Amazon and eBay with the words variator holding tool and a lot of potential options came up for around $10 to $20. The parts look the similar to the OEM variator holding tool except that they have a locking piece on the side and both of the legs move instead of just one. There are tools that are made for other scooter manufacturers to do the same thing. They have different names for them though. With a bent U-bolt to hold the clutch and a non-EOM variator holding tool I'm looking at less than $20 for what I need. I am going to order one of them, but not until I need to replace my belt and rollers. If anyone has tried one of these on a BV350 let the rest of us know how it went.
My variator holder works on both BV and Honda. The Honda is similar to the GY6, so this should work for you.
https://www.amazon.com/YunShuo-Variator-Remover-Puller-Scooter/dp/B071FG7BR2/ref=sr_1_9?ie=UTF8&qid=1506200031&sr=8-9&keywords=variator+tool
Now you have to solve the clutch holder.
Nice catch.
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Red Devil SH150i (10,000)
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Location: Orange Park Florida
 
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Red Devil SH150i (10,000)
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Location: Orange Park Florida
@bean_counter avatar
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Hooked
2016 BV350 White
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Location: East LA County, CA, USA
 
Hooked
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2016 BV350 White
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Posts: 458
Location: East LA County, CA, USA
UTC quote
Looks like this.
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2021 Primavera 150 touring, 2016 LXV 150 ie, 1978 Vespa P125, 2019 Piaggio Liberty 150
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2021 Primavera 150 touring, 2016 LXV 150 ie, 1978 Vespa P125, 2019 Piaggio Liberty 150
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Location: central Illinois USA
UTC quote
For a custom 24mm socket to fit that 'wonderful' oil plug, in that 'oh, so easy to get to' location on my 2016 Lxv I bought a regular 24 mm socket, used a gauge to measure the actual bolt head height, used black electrical tape to ring the socket, a hack saw, some time outside on the back patio, a small fine file and now own a socket that will fit on that 1/2" ratchet handle and nicely remove and re-install my lovely oil plug.
Know I prolly can't make the tools yet have, but at least you gave all of us a good start on trying.
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