BV350 factory tools, we don't need no stinking...
Post Reply    Forum -> General Discussion
Author Message
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Jul 11, 2015 9:46 am quote
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).

DSC00711.JPG

DSC00714.JPG

Addicted
2015 BV350 2007 GTS(sold) 2003 BV200
Joined: 04 Feb 2012
Posts: 752
Location: nyc
Sat Jul 11, 2015 9:54 am quote
I give this a thumbs up.

John
Hooked
piaggio hexagon
Joined: 17 Aug 2013
Posts: 449
Location: lincolnshire uk
Sat Jul 11, 2015 9:54 am 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.
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Jul 11, 2015 10:01 am 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.

DSC00687.JPG

DSC00693.JPG

Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Jul 11, 2015 10:21 am 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.

DSC00688.JPG
Tapped plates

DSC00689.JPG
Plates with 17/64" holes

DSC00690.JPG

Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Jul 11, 2015 10:32 am quote
Assembly of the clutch tool.

DSC00695.JPG
First screw one 3" headless bolt into each threaded plate.

DSC00698.JPG
Put one plate with 17/64" hole over threaded end and screw on nut.

DSC00685.JPG
Put two half pieces together like so.

DSC00683.JPG
Another view.

Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Jul 11, 2015 10:45 am 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

DSC00704.JPG

DSC00706.JPG
This is how the pins should line up.

Member
Joined: 25 May 2014
Posts: 5

Sat Aug 15, 2015 6:41 am quote
I guess the OCD is kicking in, all hole dimensions are to center line?
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Aug 15, 2015 10:58 am quote
Not much of an actor. And a 1/4-20 tapped hole is drilled 13/64 not 13/32, oops.

Addicted
Piaggio BV350
Joined: 04 May 2012
Posts: 950
Location: Mesquite, TX
Sun Aug 16, 2015 12:51 pm quote
Breaknwind,I hope you don't mind but I copied and edited the text with pix as a copy for my own use.
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sun Aug 16, 2015 1:36 pm 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.
Hooked
2016 BV350 White
Joined: 01 May 2010
Posts: 350
Location: East LA County, CA, USA
Sat Sep 23, 2017 12:02 pm 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.
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Sat Sep 23, 2017 1:01 pm 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.
Ossessionato
2014 Commuter BV350(43,000)/2015 Scoot Life BV350(10,000)/2010 El Diablito SH150i(29,000)
Joined: 27 Dec 2013
Posts: 2332
Location: Orange Park Florida
Hooked
2016 BV350 White
Joined: 01 May 2010
Posts: 350
Location: East LA County, CA, USA
Sat Sep 23, 2017 2:01 pm quote
Looks like this.

Locking Tool.jpg

Addicted
2016 LXV 150 ie, 1978 Vespa P125, 2019 Piaggio Liberty 150
Joined: 06 Jul 2016
Posts: 531
Location: central Illinois USA
Sat Sep 23, 2017 3:36 pm 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.
Scooting the Ozarks is a scooter rally held in Eureka Springs, Arkansas offering riders scenic twisty rides, poker run, and more.   Vespa Wasp Pin Badges   Scooter Parts Company
Post Reply    Forum -> General Discussion
[ Time: 0.3203s ][ Queries: 27 (0.0824s) ][ Debug on ]