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
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 Tue Feb 19, 2008 7:32 am; edited 1 time in total
Addicted
04 GT 200 smoky, 05 GT 125 smoky (in pieces)
Joined: 05 Jul 2006
Posts: 731
Location: Barcelona
Wed Feb 13, 2008 8:08 am quote
Thank you, Tommy, for the mother of all DIY threads in this forum!
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Wed Feb 13, 2008 8:19 am quote
Re-assemble the chrome cover, and the front vent with foam filter.

Pull the air filter back down, and re-mount it.

Assemble the body panels back into place.

Y, voila!

Then wash and wax, and ride like you stole it!

I had some finishing pics but.

"Sorry, you have reached your maximum Upload Quota Limit of 10 MB"

<edit> Cool, I PM'ed Jess about my quota, and he bumped me up.

Thanks Jess!

Here are my last couple of pics.

41 Re-Assembly chrome cover.JPG
Shiney!

42 Re-Assembly chrome cover.JPG
intake vent with foam filter installed.
Air cleaner dropped back inplace, and body panels installed.
Clean'er up, and ride like the wind!



Last edited by salty dodd on Wed Feb 13, 2008 1:03 pm; edited 2 times in total
Ossessionato
Joined: 13 Jul 2006
Posts: 3349
Location: pacifica,ca.
Wed Feb 13, 2008 8:21 am quote
wow.
Hooked
GT 200-His, LX150-Hers, Road King-Ours
Joined: 07 Nov 2005
Posts: 274
Location: Grand Junction, Colorado
Sat Feb 16, 2008 12:39 pm quote
Salty,

You said you cleaned the clutch pads. Is it safe to use brake cleaner on them or did you just use the scotch pad?

Thank you for posting this!!

To Jess and the moderators - This post is a great candidate to move to the technical library. What do you think?

Last edited by GJCO on Sat Feb 16, 2008 1:29 pm; edited 1 time in total
Ossessionato
Avio Gray GTV
Joined: 24 Jan 2007
Posts: 2619
Location: Albany, GA
Sat Feb 16, 2008 12:52 pm quote
quattrovalvole wrote:
Thank you, Tommy, for the mother of all DIY threads in this forum!
+1!
Enthusiast
2006 Vespa GT 200L
Joined: 23 Apr 2006
Posts: 85
Location: St Louis MO
Sat Feb 16, 2008 1:38 pm quote
Salty Dodd
Thanks so much for posting pictures of your rollers and belts. While I am not mechanically inclined in any sense of the word, I think it's a kind gesture when someone posts detailed pics and description of stuff like this. Unfortunately it doesn't help me but for those who have the tools and the inclination, seeing these pictures may save some serious and hard earned money.

Hooked
was 2006 GT200, then 2009 LXV 150, now 2012 GT300 SS
Joined: 19 Jan 2008
Posts: 107
Location: Pismo Beach, CA
Sun Feb 17, 2008 12:42 am quote
Excellent. Thank you so much. I know it was a typo, but because it could be dangerous, I wanted to make sure we clarify that you tighten the variator nut to 60 ft.lbs....not "I torqued it to 60 in/lbs."

Also, I wondered where you purchased the rollers?

Again, excellent work.

Steve
Hooked
was 2006 GT200, then 2009 LXV 150, now 2012 GT300 SS
Joined: 19 Jan 2008
Posts: 107
Location: Pismo Beach, CA
Sun Feb 17, 2008 12:46 am quote
Oops, now I see more to be worried about. You also said "I torqued the nut to ~42 in/lbs. I also torqued the trans cover screws to ~9 inlbs." Then I looked at your torque wrench and, if I'm not totally mistaken, that reads in in.lbs.

Is it possible that all your fasteners are too loose by a factor of 12?

????
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 19, 2008 7:36 am quote
Thanks all for compliments.

Zawalis, you are right, it is a typo.....corrected.

The torque wrench is measuring ft/lbs.

45 Torque wrench dial.jpg

Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Feb 19, 2008 7:41 am quote
GJCO wrote:
Salty,

You said you cleaned the clutch pads. Is it safe to use brake cleaner on them or did you just use the scotch pad?
I just used brake cleaner, and in retrospect, I should have also uses the scotchbright as well, to clean off any glazing.

It is working fine though.

I think the clutch material is the same as brake pad material. Asbestos? In order to withstand the heat involved with the friction applied.

Be certain to clean the clutch bell as well.
Hooked
GT 200-His, LX150-Hers, Road King-Ours
Joined: 07 Nov 2005
Posts: 274
Location: Grand Junction, Colorado
Tue Feb 19, 2008 11:11 am quote
salty dodd wrote:
GJCO wrote:
Salty,

You said you cleaned the clutch pads. Is it safe to use brake cleaner on them or did you just use the scotch pad?
I just used brake cleaner, and in retrospect, I should have also uses the scotchbright as well, to clean off any glazing.

It is working fine though.

I think the clutch material is the same as brake pad material. Asbestos? In order to withstand the heat involved with the friction applied.

Be certain to clean the clutch bell as well.
Thanks!!!
Addicted
04 GT 200 smoky, 05 GT 125 smoky (in pieces)
Joined: 05 Jul 2006
Posts: 731
Location: Barcelona
Wed Feb 20, 2008 2:06 pm quote
I have everything necessary to replace the belt and rollers on my GT but am not clear on what parts need to be greased after cleaning?

I have a high temperature resistant grease that I use for for high stress parts on my cars. Which Vespa parts take grease in this job? Thanks!
Ossessionato
07 GTS250(RIP), 13 GTS300, Several Lambrettas
Joined: 25 Apr 2007
Posts: 2695
Location: Raleigh, NC
Wed Feb 20, 2008 2:29 pm quote
Grease nothing inside the transmission case for a belt/roller change.
Addicted
04 GT 200 smoky, 05 GT 125 smoky (in pieces)
Joined: 05 Jul 2006
Posts: 731
Location: Barcelona
Wed Feb 20, 2008 2:33 pm quote
Thanks. Wasn't sure what Greasy meant by "dressing" the inside of the clutch bell in your thread.

So, just clean with brake cleaner and scrub the grime with a brite pad from the variator halves, roller grooves, etc.?
Ossessionato
07 GTS250(RIP), 13 GTS300, Several Lambrettas
Joined: 25 Apr 2007
Posts: 2695
Location: Raleigh, NC
Wed Feb 20, 2008 3:14 pm quote
quattrovalvole wrote:
So, just clean with brake cleaner and scrub the grime with a brite pad from the variator halves, roller grooves, etc.?
Right I also answered in the other thread:
http://www.modernvespa.com/forum/topic21158.html
Addicted
04 GT 200 smoky, 05 GT 125 smoky (in pieces)
Joined: 05 Jul 2006
Posts: 731
Location: Barcelona
Wed Feb 20, 2008 3:20 pm quote
Thanks for your help, in both threads!
Molto Verboso
2005 Vespa GT 200
Joined: 22 Feb 2006
Posts: 1007
Location: Near Tyler, Texas
Thu Apr 17, 2008 2:14 pm quote
Malossi rollers vs. OEM rollers
I am about to change out my belt and rollers on my 2005 GT200, using Malossi 12.5 gm 20x17 rollers. I read about your placing a certain end of the new rollers to the right at 12 O'clock. Here's what the Malossi instructions say about their rollers: "...Place the assembly into the variator pulley observing that the 'Malossi' writing, on the edge of the plastic holder, faces the opposite direction of the variator pulley rotation." There is a diagram on the package showing the roller being inserted into a plastic sleeve or something. There are no plastic sleeves on the GT200 OEM rollers, correct?

This is confusing to me. Do I put the end with the Malossi writing on the right or left starting at 12 O'clock?
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Tue Nov 25, 2008 12:04 pm quote
Re: Malossi rollers vs. OEM rollers
FarSideMan wrote:
I am about to change out my belt and rollers on my 2005 GT200, using Malossi 12.5 gm 20x17 rollers. I read about your placing a certain end of the new rollers to the right at 12 O'clock. Here's what the Malossi instructions say about their rollers: "...Place the assembly into the variator pulley observing that the 'Malossi' writing, on the edge of the plastic holder, faces the opposite direction of the variator pulley rotation." There is a diagram on the package showing the roller being inserted into a plastic sleeve or something. There are no plastic sleeves on the GT200 OEM rollers, correct?

This is confusing to me. Do I put the end with the Malossi writing on the right or left starting at 12 O'clock?
I don't know about the Molossi rollers, I just made note of how the OEM rollers came out so I could put the new ones back in the same way.

There is a side that has the rubber or plastic, and a side with metal showing.
Hooked
Vespa GTS 300
Joined: 05 Oct 2008
Posts: 207
Location: Lawrence, Kansas
Sun Jan 04, 2009 1:37 pm quote
possible method of cleaning pulley halves
I do a lot of lathe work, and one of my lathes has a sliding reeves drive, much like the CVT on the the Vespa. The original belts for this 1951 model lathe are no longer available, so I use an "equivalent" snowmobile belt which gunks it up from time to time. When it does, I pull the halves off, chuck them in another lathe, and while spinning, clean them with a scotchbrite pad. It takes about 30 seconds, and if there are any grooves or ridges, I can polish them out (these parts are made of bronze). Hope this is useful to someone.
Enthusiast
G.T 200 (Granturismo)
Joined: 04 Jan 2009
Posts: 63
Location: Ice Box MN
Sun Jan 04, 2009 11:49 pm quote
You were lucky...
as I only got 8,000 miles out of my first belt before it exploded into a million small pieces. At first I had no idea what happen but I came to a stop pretty quick.
Fortuneatly I only pushed it about a quarter of a mile before a cool guy in a truck with straps stopped. We lifted the damn thing in the back of his truck and I got a free ride home!
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Sat Apr 23, 2011 11:14 am quote
GT200 belt replacement.
Followed your step by step instructions ....great job!

Back on the road.

N.B My original belt was a ball of fluff when I removed the cover.

I fitted an after market generic belt. This item only had "teeth" on the inside...yours has teeth on the inside and outside!

Is yours an original Piaggio belt?

Thanks and regards Dan
Addicted
GRAPHITE LX 150
Joined: 10 Jun 2009
Posts: 762
Location: delaware, Bethany Beach
Sat Apr 23, 2011 1:29 pm quote
better PM the author, you're the 1st to comment in 2 yrs.
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Tue Apr 26, 2011 9:11 am quote
PM ?

What does this mean?

I am English!

Regards M
World Traveler
2007 LX150 Daring Plum Leonardo Da Vespa
Joined: 02 Jul 2006
Posts: 29304

Tue Apr 26, 2011 9:16 am quote
It means Private Message. Look at your post and in the lower left bottom you'll see a box that says pm. Just click on it from the person you want to ask somethings post and ask away. hen the person answers you you'll see a 1 after the word message in the upper left line of things, forum. wiki etc. Hope this helps.
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 38568
Location: Pleasant Hill, CA
Tue Apr 26, 2011 10:14 am quote
Re: GT200 belt replacement.
In the meantime I'll answer...
Maicoletta wrote:
I fitted an after market generic belt. This item only had "teeth" on the inside...yours has teeth on the inside and outside!

Is yours an original Piaggio belt?
Yes, his was. Current part number 840908 for the GT200 - plus you'll have needed that all-important one-time-use variator nut.

I'm wondering how much you paid for this after-market belt (and why you bought one) - I paid GBP40 inc VAT for the correct OEM one, and I've never known an aftermarket belt last as long as the OEM. So please do keep an eye on it...
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Tue Apr 26, 2011 11:55 am quote
I thought PM meanT Post Meridian!!

Anyhow...I paid 20 for the belt. It is a French made generic type that fits loads of autos. I did NOT fit a new variator nut..but torqued it up accordingly and used copius amounts of bearing lock.


Why did I pay 20?...probably because I am a tight git and I have been away in Germany ..so I got the belt by post (deivered during my absence) off a company in Wales! My nearest Vespa dealer is thirty miles away..so I guess I will just suck it and see!

You have got me worrying about that nut!

Not a 200...but a nice 250 from an ex member of our Scooter Club!



Regards Maicoletta!

Last edited by Maicoletta on Tue Apr 26, 2011 12:00 pm; edited 1 time in total
Hooked
gt200,px125,gp150,gp200
Joined: 27 Sep 2009
Posts: 228
Location: United Kingdom
Tue Apr 26, 2011 11:56 am quote
used this thread last week to install belt-rollers etc
was a great help
thanks
fantastic and easy to follow
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Wed Apr 27, 2011 10:04 am quote
GT 200 info please
Took the scoot out to work and back today.....first time out since the belt refit.

A big drop in performance is apparent. The scoot seems to hold back at full pelt and will just hold "a nudge" under 70 ( it used to cruise at 75mph).

Any one any ideas on this phenomenon. ( I did not change the plastic rollers)

I am on a steep learning curve with "autos" so any help would be appreciated by you chaps in the know!

regards Maicoletta
Hooked
gt200,px125,gp150,gp200
Joined: 27 Sep 2009
Posts: 228
Location: United Kingdom
Wed Apr 27, 2011 10:11 am quote
Re: GT 200 info please
Maicoletta wrote:
Took the scoot out to work and back today.....first time out since the belt refit.

A big drop in performance is apparent. The scoot seems to hold back at full pelt and will just hold "a nudge" under 70 ( it used to cruise at 75mph).

Any one any ideas on this phenomenon. ( I did not change the plastic rollers)

I am on a steep learning curve with "autos" so any help would be appreciated by you chaps in the know!

regards Maicoletta
sorry i have no answer but your not alone
mines the same seems a drop in top end power
the theory here is that the new belt needs a few miles on it to bed in

would like to know if anyone has a deffinate answer
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 38568
Location: Pleasant Hill, CA
Wed Apr 27, 2011 10:12 am quote
Your generic belt is undoubtedly 1mm or so lacking in width. If the speed hadn't dropped before, it's probable the rollers aren't too bad - but they can give the same symptoms if badly worn.
Veni, Vidi, Posti
2007 LX 150 (memories)
Joined: 12 Jun 2007
Posts: 8290
Location: New Hampshire
Wed Apr 27, 2011 10:13 am quote
It could be the aftermarket belt.
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Wed Apr 27, 2011 1:08 pm quote
Q. What is the purpose of the plastic rollers?


They seem a rather token gesture ,as a method of alleviating friction ...if that is what they are supposed to do.

Better get my old 850 Guzzi out of retirement!

Regards Maicoletta
Veni, Vidi, Posti
2007 Vespa LX 190, 2011 LXV150ie
Joined: 26 Oct 2008
Posts: 8659
Location: Annapolis, MD, USA
Wed Apr 27, 2011 2:00 pm quote
Maicoletta wrote:
Q. What is the purpose of the plastic rollers?


They seem a rather token gesture ,as a method of alleviating friction ...if that is what they are supposed to do.

Better get my old 850 Guzzi out of retirement!

Regards Maicoletta
The rollers are what control the shifting of the CVT automatic transmission. They are actually plastic-covered weights (you'd notice that they had a metal core) that are pushed outward in their ramps by centrifugal force as engine speed increases to force the moveable half of the driving pulley against the fixed half. This increases the effective diameter of the driving pulley (as the spring-loaded driven pulley does the opposite). This is what effects the gradual shifting from low to high gear.

The plastic covering does reduce friction as the weights slide in their ramps, as well as preventing wear to the ramps and back plate. If bad flat spots are worn into the plastic, their effective diameter is decreased, and they will neither move as smoothly nor shift the transmission into as high a gear.
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 38568
Location: Pleasant Hill, CA
Wed Apr 27, 2011 2:38 pm quote
However, true as that may be, that isn't the problem here. The problem is spend cheap, spend twice...
Addicted
2007 Vespa GT200
Joined: 05 Mar 2011
Posts: 583
Location: Southern California
Wed Apr 27, 2011 6:45 pm quote
Re: GT200 belt replacement.
jimc wrote:
In the meantime I'll answer...
Maicoletta wrote:
I fitted an after market generic belt. This item only had "teeth" on the inside...yours has teeth on the inside and outside!

Is yours an original Piaggio belt?
Yes, his was. Current part number 840908 for the GT200 - plus you'll have needed that all-important one-time-use variator nut...
I was following this great thread...truly an amazing post. I have the service manual for the GT200 and it is not nearly as helpful. Should have given the author an MV Award of Excellence!
Hooked
Yes, I am a scooter model
Joined: 06 Jan 2011
Posts: 459
Location: Southwest United States
Wed Apr 27, 2011 7:03 pm quote
Outstanding tutorial!!
Member
Vespa GT200
Joined: 17 Apr 2011
Posts: 19
Location: Lincolnshire U.K
Wed Apr 27, 2011 9:55 pm quote
The missis is having a load of her mates over on Friday...we have a holiday tomorrow.....due to you know what!

Looks like I will be in the shed with the Vep doing a post mortem!

( P.S being a yorkshiremen means I am "as a tight as a camels you know what" in a sandstorm.... I find spending cash extremely painful!)

Many thanks for the advice and the guidance.

P.S the belt was OEM certified.
Hooked
2006 GT125
Joined: 03 Feb 2011
Posts: 284
Location: Cork, Ireland
Thu Apr 28, 2011 5:44 am quote
What an excellent post and thread, I have been engrossed in it for the last day or so. Very descriptive, great photos and It has given me the confidence to give this procedure a crack in the near future
Salty Dodd- Well done sir, an excellent piece of work. he who shares his knowledge is a prince among men
Speaking of- The variator nut: Is it ABSOLUTELY necessary to replace it each time or will I get away with it for one change out (I'll have to order it in from the UK if it's required)
Molto Verboso
(GT200L) ... no more scoot :o(
Joined: 15 May 2006
Posts: 1168
Location: Riverside, CA, USA
Fri Apr 29, 2011 12:48 pm quote
Thanks all!

I've been told, the best way to tell if you've learned something is to see if you can teach it.

Some have commented if you use loctite, then re-using the nut is ok, but they are readily available here in Southern Califorrnia.

Glad to see that this thread is doing some good.

I know I should take the time and make it a wiki report.
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