GT200 CVT belt and rollers replacement.
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Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Jan 21, 2008 8:50 am quote
<edit> Changed title.

I lost my belt this morning 11265 miles!

Iíve had a new one, and new rollers, for some time now but have been lazily putting it off.

I havenít bought the proper tools for the replacement yet either.

The weather has been so nice lately, Iíve just been twisting and going.

So on my way into work this morning, I am going WOT with very little traffic due to the MLK holiday.

As I pass the 60 FWY, I lost all power to the rear wheel, and the motor was still running.

I new immediately what had happened; I am glad that the rear wheel didnít lock up on me, as Iíve read happen to others on this board.

I coasted past the FWY on ramp, and only had to push it a few yards before making it to an area where I could have my son come with the truck, and pull over with enough room to load her into the back.

I called my son, and he was there with my truck in a bout 20 minutes. Fortunately I only commute about 15 miles, one way.

He dropped me off at the office, and I will get a ride home from someone here.

Iíll take pics, as I go through the repair, and post, later.

I need to put the tools on order too. Unfortunately Max is not open today, Monday.

Last edited by salty dodd on Mon Feb 11, 2008 12:12 pm; edited 2 times in total
World Traveler
2007 LX150 Daring Plum Leonardo Da Vespa
Joined: 02 Jul 2006
Posts: 29304

Mon Jan 21, 2008 10:13 am quote
Hope you get her up and running soon. We need to speak to max about having days off
Gobshite Shiva
Kymco Downtown 300i the 'Dolphin Noise'
Joined: 16 Mar 2007
Posts: 14958
Location: London UK
Mon Jan 21, 2008 10:45 am quote
eeek! i bet that was a bit scary. sounds like it all worked out okay for you though.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 12:13 pm quote
Ok,

I finished replacing the belt and rollers, and will now attempt to report on it.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 12:17 pm quote
Max didn't have any clutch holding tools in stock so I made one.

Here are the details: GT200 / GTS 250 Clutch Holding Tool.

And here is a much simpler one, that I don't see why it would not work: Homemade clutch holding tool

Clutch Holding Tool.JPG
Made from two bolts, and some sort of construction washer.

washer and bolts on scoot.JPG
On the scoot.



Last edited by salty dodd on Tue Feb 12, 2008 1:46 pm; edited 2 times in total
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 12:45 pm quote
Removed the trans cover after removing the clutch nut and washer.

Removed Clutch nut.JPG
Used torque wrench to remove clutch nut and washer

Removed intake filter 1.JPG
Removed intake filter.

Removed intake filter 2.JPG

Removed intake filter.JPG

Removed housing screws 1.JPG
Invaluable tool after many years of motocycle maintenance, a torque driver.

Removed housing screws 2.JPG
The front screw has a ground wire attached.

Belt debris in housing 1.JPG
Disintegrated belt, once cover was removed.

Belt debris in housing 2.JPG

Belt debris in housing 3.JPG
Note how I placed the screws on the ground in the order of removal.
I then placed each one back into itís respective hole in the cover since I would need to come back another day.
The screws turned out to be the same size all around, but I do this in case

Belt debris in housing 4.JPG

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 12:49 pm quote
Oh, buy the way, Moped, I tried your trick of just rotating the air filter forward by leaving the forward screw in place, but found that I had to remove the front screw as well in order for the housing to clear for removal.

Undid air filter and moved it up 1..JPG



Last edited by salty dodd on Mon Feb 11, 2008 3:39 pm; edited 1 time in total
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 12:56 pm quote
Someone other than Max filled my order, and sent me the variator tool for the GTS instead of the GT.

I called, and spoke with Max.

He had me send it back and he sent the correct one in parallel.

Variator Tool 1.JPG
Housing off, annd clutch removed with most of the debris removed.

Variator Tool 2 GTS.JPG
GTS Variator tool
(Wrong tool for GT200)



Last edited by salty dodd on Mon Feb 11, 2008 3:40 pm; edited 1 time in total
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 1:07 pm quote
When I recieved the correct tool, I new it needed a mod to be used on the GT vs. the LX, but didn't know where.

These pics show the mod and where.

I made the mod in our model shop at work.

No tool.JPG
No tool in place. Tool mounts in these two holes. A pin goes into the upper counter bore.

tool no mod.JPG
Red line shows direction of mod.

With tool no mod.JPG
You can see the misaligned hole, and where clearance is needed. The pin is inserted into the upper counterbore.

With tool no mod closeup.JPG
Close up.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 1:13 pm quote
Modified tool.

Front side.JPG
Front side.

Back side.JPG
Back side. Sorry for the poor focus.
I took the slot up to the wall of the cylindrical feature on the back side.

Tool in place.JPG
Tool in place using one of the housing screws to mount it.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 1:14 pm quote
I've run out of lunch time, so I'll pick back up later.
Ossessionato
07 GTS250, Several Lambrettas
Joined: 25 Apr 2007
Posts: 2627
Location: Raleigh, NC
Mon Feb 11, 2008 1:23 pm quote
Was that a stock belt or an aftermarket?
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 1:28 pm quote
That was the original stock belt.

I should have replaced it long ago.

I had the new one in the garage, but procrastinated.
Ossessionato
Vespa GTS 250ie, and a GO-PED hehe!
Joined: 20 Nov 2006
Posts: 3752
Location: cleveland, UK.
Mon Feb 11, 2008 1:46 pm quote
its a bad thing to happen when your 300 miles away from home.... luckily mine snapped outside a dealer

good luck on getting her going again.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 2:11 pm quote
suit scoot wrote:
its a bad thing to happen when your 300 miles away from home.... luckily mine snapped outside a dealer

good luck on getting her going again.
Thanks, she is goin' again.

I rode her into work this morning.

I was just reporting on the replacement of the belt, and will finish the report later.
Member
Typhoon 50, Vespa GL, ET3, Rally 200, & GTS, Gilera Runner 180, KTM 525, Suzuki DRZ400, Buell XB12X, Honda Ruckus, Honda CB400F
Joined: 28 Aug 2006
Posts: 46
Location: San Diego, CA
Mon Feb 11, 2008 2:25 pm quote
Whenever you snap a belt, I would recommend taking the driven pulley apart, to verify the pins have plenty of grease and are not worn. Sometimes the belt snaps because the driven pulley binds up.

Here is a dirty trick to hold the drive pulley on ET4, LX150 and GT200s: wedge a #4 Philip's screw driver between the starter sprocket(very large) and the engine case at the 5 o'clock position. I would never do this on a customers bike since I have the factory tools, but at home I have used this trick on my own scooters. Also the drive pulley center nut should be replaced every time it is removed, if you don't have a replacement use red lock tite on the threads. It is not pretty when that nut comes loose.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 3:29 pm quote
moto-scoot wrote:
Also the drive pulley center nut should be replaced every time it is removed, if you don't have a replacement use red lock tite on the threads. It is not pretty when that nut comes loose.
Now you tell me.

It was mentioned in this thread that it was ok to re-use the nut, so I did: Variator & Belt change - Pictures from MV workshop

And no loctite was mentioned.
moto-scoot wrote:
Whenever you snap a belt, I would recommend taking the driven pulley apart, to verify the pins have plenty of grease and are not worn. Sometimes the belt snaps because the driven pulley binds up.
I think mine snapped because I was pushing the smilage.
Member
Typhoon 50, Vespa GL, ET3, Rally 200, & GTS, Gilera Runner 180, KTM 525, Suzuki DRZ400, Buell XB12X, Honda Ruckus, Honda CB400F
Joined: 28 Aug 2006
Posts: 46
Location: San Diego, CA
Mon Feb 11, 2008 3:55 pm quote
11k miles is quite a long time for one belt, I have seen a few snap before 6k miles.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Mon Feb 11, 2008 4:13 pm quote
moto-scoot wrote:
11k miles is quite a long time for one belt, I have seen a few snap before 6k miles.
I know...
Addicted
06 GT200(black graphite)
Joined: 05 Jun 2006
Posts: 603
Location: OKC ,OK
Mon Feb 11, 2008 4:26 pm quote
I have a new belt and rollers sitting on top of my toolbox right now, have been for awhile now. Just hit 7k and almost all of my mileage is at highway speed. After seeing your post I WILL be doing some maintenance this weekend.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 7:20 am quote
Variator half pulley removal.

01 Nut w-spring washer.JPG
The manual said to replace the nut, but I didn't. Others said they were not too concerned. I will get a new nut next time, and I would have used the loctite, had I known.

02 Nut w-spring washer 2.JPG
It has an integral spring washer.

03 starter engagement gear.JPG
The starter engagement gear slid off with a small amount of effort.
I had to remove the oil filler cap for clearance.

04 starter gear removed.JPG
Outer variator pulley next.

05 drive pulley needs clean.JPG
Rather grungy. Needs cleaning with brake cleaner.

06 More debris.JPG
More debris.
Note the washer.

07 debris removed, washer in place.JPG
Debris removed. Washer still in place.

08 washer removed.JPG
Washer removed.
Bushing visible.

09 back half pully w-rollers.JPG
Back of inner half pulley with rollers in place.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 7:26 am quote
The little yellow things were a little tricky to re-assemble.

They have a specific purpose, and I'll explain with the re-assembly.

10 Half pullies removed.JPG
Inner half pulley removed, bushing still in place.
Note the orientation of the little yellow things.

11 Half pullies removed.JPG
Bushing removed.
You can see where the rollers engage and wear on the conical plate.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 7:46 am quote
Several views of the driven pulley assy.

<edit> I've figured out how to make the pics a little bigger.

01 driven pulley.JPG
Needs cleaning.

02 driven pulley.JPG
Clutch pads visible.

03 driven pulley.JPG
Note the spring between the clutch and the outer driven half pulley.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 7:54 am quote
Some shots of the rollers in the inner variator half pulley.

04 rollers.JPG
At the 12 o'clock position, the metalic side of the roller is to the right.

05 rollers.JPG
Blurry shot of the metal side.

06 rollers.JPG
Other, plastic coated side of the same roller.

07 rollers.JPG
Flat spots were worn into the rollers.
Some were worse than others.
Some not too bad.

08 rollers removed.JPG
Rollers removed.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 8:20 am quote
Cleanup!

I used brake cleaner, and green scotchbright pad, as recommended in Michael Moore's thread.

09 Cleanup outer half pulley.JPG
There was a ring that was particularly difficult to clean.
I do most of my riding commuting on the freeway, WOT, so I think the belt rides high on the driving pulley

10 Cleanup outer half pulley.JPG
This is as best that I cleaned it.

11 Cleanup inner half pulley.JPG
Eeeeew!

12 Cleanup inner half pulley.JPG
Cut a small piece of scotchbright pad that fit the roller slots.

13 Cleanup inner half pulley.JPG
Shiney!

14 Cleanup clutch.JPG
Driven pulley assy.
I hit the two half pullies, as well as the clutch pads.

15 Cleanup all three.JPG
Pretty shiney things.

16 Cleanup CVT housing.JPG
Cleaned inside the housing.
I was still pulling debris out as I was assembling.

MV Saint
Haud yer wheesh't if ye cannae be nice
Joined: 12 Aug 2007
Posts: 3864
Location: Camden, Maine
Tue Feb 12, 2008 8:29 am quote
Salty, What a great write-up and pics Keep them coming.

This is the MV i like

Cheers
Hooked
some scooters & a bonnie black
Joined: 07 May 2007
Posts: 290
Location: Clumpus Ohio
Tue Feb 12, 2008 8:55 am quote
GT owner here.

My hat's off - great post!
Enthusiast
Vespa GT 200
Joined: 19 Oct 2007
Posts: 73
Location: Western NY
Tue Feb 12, 2008 10:44 am quote
+1 on the great posts. A fellow GT owner as well , I really appreciate your efforts in posting the whole process. And pics too, even better! Can't wait to see the thrilling conclusion.

I really get a kick out of the friendly back and forth of the Royal Bastards and others, but this detailed technical tutorial stuff is the real reason that I rarely miss a day without checking the MV posts.

Best regards, Big Jim
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 12:53 pm quote
Thanks, guys.

I agree, this forum is great for the tech stuff, and Iím just tryiní to do my part.

Following Michael Mooreís thread really helped me. Variator & Belt change - Pictures from MV workshop

I just wanted to get the details of doing the GT. There are a few differences.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 1:15 pm quote
On top of it all, while I was taking photos for this report, I am glad I was doing so.

I had to refer back to the photos to ensure re-assembly being correct.

Last edited by salty dodd on Tue Feb 12, 2008 1:36 pm; edited 1 time in total
Moderator
2006 LX150 "Amadora"
Joined: 01 Feb 2006
Posts: 7129

Tue Feb 12, 2008 1:18 pm quote
This has been a very nice thread to read! It almost makes me feel capable of tackling something similar on my LX. Thank you for your time and effort in putting it together!
Hooked
2007 Plum GT "Stephanie"
Joined: 22 Dec 2007
Posts: 278
Location: north florida
Tue Feb 12, 2008 2:04 pm quote
Another BIG + for the step by step and great pictures----this will certainly make the job a lot easier when Stephanie gets to the point of needing a belt and a little internal cleaning. I think I will get the necessary parts before hand tho. Art
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 2:46 pm quote
Ok, re-assembly.

17 Re-Assembly Kona.JPG
First get your best buddy, and a delicious beverage of choice.

17 Re-Assembly rollers.JPG
Rollers installed with metal side to right at the 12 oíclock position.

18 Re-Assembly rollers.JPG
Follow suit around the clock.

19 Re-Assembly bushing.JPG
Assemble bushing on.

20 Re-Assembly bushing.JPG
The yellow plastic things donít want to stay in place very well.

21 Re-Assembly bushing.JPG
Sittiní pretty.

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 3:18 pm quote
Ok,

Here is a tricky part, and where I explain the yellow plastic things.

The yellow plastic things mate with the rectangular features shown.

So you have to get the inner half pulley, with the rollers in place, onto the shaft, and then onto the bushing.

Donít slide it on all the way yet.

The tricky part is getting it onto the bushing without the yellow things falling out of their slots, and then making certain that the rectangular feature is aligned with the yellow things.

It took a couple of tries but it was doable without too much aggravation.

22 Re-Assembly Inner half pulley.jpg
Inner half pulley with rollers.

23 Re-Assembly Inner half pulley.jpg
Yellow plastic things mate with the rectangular features on the inner half pulley.
Still some debris to be removed.

24 Re-Assembly Inner half pulley.JPG
Y, voila!

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 12, 2008 4:01 pm quote
<edit> Here is an important point to take note of before proceding to the next step. When you place the belt between the pulleys, be certain that when you hold it in place, you can read the printing on the top of the belt. If the printing is backward, or upside down, it is on backward. I made this mistake the first time, and had to pull it apart and correct it.

Now here is another tricky part.

Getting the half pulleys separated, and the belt pushed in to hold them apart.

This is where your best buddy come into play.

Though Kona was unable to help with his paws, he was there with moral support.

He also snuck in a couple of smooches while I was on the ground.

I inquired the help of Salty Dawn, and she did smashingly well.

I placed the driven pulley assy on the ground as shown.

With my thumbs, I pushed where indicated toward the ground, at the same time rotated against the spring, counter clockwise, while Dawn pressed the belt toward the center of the pulleys.

Once she pressed the belt in, it held the pulleys apart.

To ensure they stayed apart, I pinched the belt together as shown.

It did slip out, and I had to do it a second time, while I was assembling it onto the shaft, but it eventually worked out.

25 Re-Assembly Belt on driven pulley.jpg
Place the assy on the ground, as shown.
You press on the lower pulley, toward the ground.

26 Re-Assembly Belt on driven pulley.JPG
Pinch the belt together, to prevent the belt from slipping out.

27 Re-Assembly Belt on driven pulley.JPG
Slide the whole shootin' match onto the spline, as shown.



Last edited by salty dodd on Mon Nov 24, 2008 1:30 pm; edited 1 time in total
Ossessionato
07 GTS250, Several Lambrettas
Joined: 25 Apr 2007
Posts: 2627
Location: Raleigh, NC
Tue Feb 12, 2008 4:05 pm quote
Your tricky part is easier if you remove the backplate (with the three sliding bushings) of the variator, assemble it your hand, then push the assembly onto the crank. Then intall the sintered bearing (gudgeon pin), just make sure its all the way in.

Also it looks like you might have installed the belt backwards. Some have arrows, but the easiest way is you should be able to read the writing (not upsidedown) when it is on the scooter.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Wed Feb 13, 2008 7:20 am quote
starreem wrote:
Also it looks like you might have installed the belt backwards. Some have arrows, but the easiest way is you should be able to read the writing (not upsidedown) when it is on the scooter.
Shnickies!!!! I see what you mean.

I had read the correct orientation in another post somewhere, but did not remember to do so.

I wonder what the detriment of running it backward might be?

43 Re-Assembly belt writing.JPG
This pic shows the numbers being read backward.



Last edited by salty dodd on Tue Nov 25, 2008 8:59 am; edited 1 time in total
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Wed Feb 13, 2008 7:23 am quote
starreem wrote:
Your tricky part is easier if you remove the backplate (with the three sliding bushings) of the variator, assemble it your hand, then push the assembly onto the crank. Then intall the sintered bearing (gudgeon pin), just make sure its all the way in.
And I follow you on this statement, as well.

I didn't pull the backplate off. What you say makes sense.
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Wed Feb 13, 2008 7:39 am quote
Well, I'll continue with the finishing of the assembly procedure.

This is where I was glad to have been able to go back to the pics.

I could not remember where the washer goes onto the driving pulley assy. It goes between the two half pulleys.

28 Re-Assembly Belt on driven pulley w-washer.JPG
Washer assembled onto the driving pulley assy.

29 Re-Assembly Belt on driven pulley w-washer.JPG
Another shot showing the printing going in the wrong direction.
With the washeer assembled onto the driving pulley assy.

30 Re-Assembly Belt on driving pulley.JPG
Then the outer half pulley.

31 Re-Assembly Belt on driving pulley.JPG
It has an o-ring on the outer circumference.
Possibly for air flow across the fins.

32 Re-Assembly starter gear.JPG
Then the starter motor engagement gear.
I may not be calling these parts by their correct name according to the manual, but they make sense to me.
Please forgive.

33 Re-Assembly starter gear.JPG
Engaged with the variator holding tool. I reviewed the pics and ensured that the outer pulley, and the starter gear back on in the same orientation. Note the arrows on the gear. There were some similar marks on the pulley as well. Balance.

34 Re-Assembly starter gear w-nut.JPG
Nut back on.



Last edited by salty dodd on Tue Nov 25, 2008 9:00 am; edited 1 time in total
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Wed Feb 13, 2008 8:04 am quote
Torque the nut.

Here are the torque values from the manual.

I am not certain what the rear hub cover screws are.

35 Re-Assembly Shop Manual torque values.JPG

35 Re-Assembly starter gear torque.JPG
I torqued it to 60 ft/lbs.

36 Re-Assembly clutch bell.JPG
slide the clutch bell on.

37 Re-Assembly CVT housing.JPG
CVT housing cleaned up, and debris removed.

38 Re-Assembly CVT remove tool.JPG
Remove the variator holding tool.

39 Re-Assembly CVT housing.JPG
Housing assembled on.
Note the two brakets holdeing the brake line on the bottom.
Also don't forget the ground wire on the front screw.

40 Re-Assembly clutch nut torque.JPG
Home made clutch holding tool.
I torqued the nut to ~42 ft/lbs.
I also torqued the trans cover screws to ~9 ft/lbs.



Last edited by salty dodd on Mon Jan 11, 2010 2:18 pm; edited 1 time in total
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