You need a torque wrench that can read up to about 150 lb/ft. You can get by with one that only does 50 lb/ft with the work around I highlight below.
Socket wrenches, ½" and 3/8" drive, 21mm, 27mm, 10mm and 8mm sockets
Phillips head screwdriver
You need to make a special tool to hold the CVT still while tightening its nut. I have a picture below that you can print out or (preferred) download the pdf at the end of this article.
You need a 1/8" thick, 6 1/2" x 7 1/2" [3mm thick, 165mm x 190mm] plate of aluminum to make the tool.
You also need:
19 ea M6 x 25mm screws
3 ea M6 x 50mm bolts
3 spacers with 1/4" [6.2mm] ID and a length of about 1 7/16" [37mm].
Print out the template. Make sure the length and width of the template are 6 1/2" x 7 1/2" [165mm x 190mm].
Template jpg...there is also a pdf at the end of the article
Using the printout as a guide, drill all holes with a 1/8" [3mm] bit. Drill all 19 holes in the circular pattern with a .201" [5.1mm] bit. Drill the center main hole with a 1 1/2" [38-40mm] bit, and the 3 along the edges with a .240" [6.1mm] bit. Tap all 19 holes with an M6 x 1.00 thread. Screw all 19 M6 screws into each of the threaded holes. I got a little anal and covered all the screw threads with vinyl tubing. The finished tool should look something like the pictures below:
Tool: Front and Back
Removing the side cases required removal of four screws (M4 allen).
The fuel saddle plastic has four screws that hold it in place. Two are concealed under the fuel filler door and the other two are at the right and left corners. Remove the fuel filler cap and drip shield. Slide the plastic up in front and remove it from under the body panel at the rear. Replace fuel cap while doing the remaining work.
The side plastic is removed by removing the rubber mat (it pops up and out), removing two screws under it, three screws at the front wheel end of the panel, two screws that were concealed under the fuel filler saddle, and one screw under the foot "peg" for the passenger.
Lift side plastic up and off. Set aside. Your scoot should now look like the figure below.
Top: Saddle up. Note screws concealed left and right.
Middle: Screws under rubber mat
Lower: Side plastic off
Remove the transmission plastic cover. Four Philips screws; use #2 Phillips driver.
Your scoot should now look like:
Top: Removing Dust Cap
Middle: Removing Transmission cover (taken from Piaggio Manual)
Lower: Cover off
Remove the transmission housing. There are four main bolts (10mm socket), and an array of bolts along the edges (M8 socket). The cover should now come off. I had to lightly tap the driven shaft end to get it to come off. If you do the same, use a plastic hammer and be gentle. There are two washers that will come off the driven shaft. Don't let them get away from you!
Your scoot should now look like
Top: Removing driven nut
Middle: Washers and housing
Lower: Step 3 done
Pull off clutch bell. Check inside for any abnormal wear. You should check for wear and runout. The nominal ID is 4.069" [160.2mm] with a max ID of 4.076" [160.5mm]. Measure the diameter at several places. The allowable runout is .008" [0.2mm]
Top: Removing washer from driven shaft
Bottom: Inside of clutch bell
Use a 27mm socket and remove the center bolt. This may require a breaker bar on your ½" socket drive. The nut is on seriously tight. My impact driver could not get it off! I ended up using a 4' long / ¾"ID pipe over my socket drive to get it done. Once the nut is loose, remove the special tool.
Once the tool is off, remove the washers.
Top: Special tool properly installed
Middle: Placement of socket wrench through special tool
Lower: Removing washers from CVT
Next slide off the near side of the CVT. It simply sides off.
Check for any abnormal wear. Clean if needed. Make sure you don't get any oil on it. If you do, wipe off immediately with alcohol.
Top: CVT near side after sliding off
Lower: CVT side should be smooth and clean
Transmission housing without a transmission!
The sleeve you now see moves freely. Don't remove it yet.
Top: Remove washer
Bottom: The sleeve I am talking about
The rear half of the CVT is free to slide out. Slip some fingers behind it and hold the roller cage in place while pulling the CVT rear off. Hold the roller cage in place the whole time.
Now look at the back side to see what you were holding. Make a note of how the sliding guides are fixed into the metal cone so you can replace them properly.
Place on a work surface with the roller cage side upwards.
Top: Slip fingers behind to hold roller cage
Middle: The roller cage
Bottom: Assembly on bench, roller cage side up
Set the cage on your work surface. You can now see the rollers.
One by one remove a roller, clean the inside of each roller's running area, and replace with a new roller.
Top: Lifting roller cage. Note plastic guides around cage
Middle: The rollers!
Bottom: Lifting the sorry rollers out
Note that the rollers are different on one side than the other. Be sure to replace the rollers with the same orientation they had from the factory.
When you are done, the assembly looks like this.
I also cleaned the internal steel sleeve. It was gunky. The manual warns against lubricating or cleaning the inside of the bronze bearing it rides in.
Now, while holding the plastic guides in place, fit the roller cage back over the rollers.
Top: If you look carefully one side shows the bearing, the other side does not
Middle: All pretty now
Bottom: The sleeve after I cleaned it
Top: Squeezing the clutch and pressing the belt into it
Bottom: How far I pushed the belt in
Install the special tool. Using the 27mm socket, tighten to 120-130 lb/ft [160-175NM]. My torque wrench did not go that high. I used a 25 lb weight (bucket of water) at the end of my 4' bar to set the torque. You can use some loctite to keep the nut from coming undone. Its also a good idea to mark the position of the nut with a dab of paint so you can tell if its coming undone in future inspections.
It looks crazy, but it works well
Don't forget the washer.
Place transmission housing over the transmission, aligning the bearing over the driven shaft. Loosely install all bolts (four large ones first). Now finger tighten all bolts. Tighten the large bolts to 17-19 lb/ft [23-26NM] and the small ones to 8-10 lb/ft [11-13NM].
Install two washers (smaller one first) and nut over the driven shaft.
Now the manual asks you to hold the center shaft while turning the nut to prevent torque from loading (and potentially damaging) the final drive. I did not do that. I held the left brake firmly while tightening the 21mm bolt with a torque wrench. I deemed this safe. You may not agree with that. Tighten to 68-75 lb/ft [92-100NM].
Top: Clutch bell going back on
Middle: The washer
Bottom: Don't forget the washers outside the transmission housing
Install round dust cap.
Position plastic transmission cover over transmission and reinstall 4 phillips screws.
Reinstall air filter cover.
Reinstall skins. You're done. Whew!
The crack that really kinda scared me!
The shop that had performed the inspection at 10,000 miles had done a terrible job. Several of the plastic screws were not reinstalled or installed wrong. They also broke off one of the plastic standoffs inside my air filter. They stripped two of the screws that hold on the plastic transmission cover. It was also apparent that they had used an impact wrench to perform all the bolt removals and reinstalls. ARGGGH!!!!
It is these types of consistent incompetence from most every scooter service shop I have used that drives me to do these reports for the community.