Over Range kit installed & a new how to

[marylandmark]

3.5 Installing Variator... Place 3.8g rollers into variator, place bushings on variator and place back plate onto varitator... Install the metal pin (that the variator rides on) and place belt over (final install) shaft... Then install the finned variator pulley and kick start gear! That's it for the Variator...

Why those rollers? Do you think changing them will improve performance? What I am getting at is this going to save the "eternal weight changing with a regular variator" issues or is it going to be the same old thing- try these weights, then these weights, then a combo of the 2 and so on...



7. Follow the instructions for assembling the rear pulley... Basically, there are 6 slot cut into the torque driver... 3 are angled more than the others... It says to use the most angled but my scooter stalled with that set up... so I went with the lesser of angles... Place the 3 pins into the holes in torque driver... Grease the torque driver and place the spring cap in place...

So.. It says to go with the most angled ones but you went with the lesser angled ones because you stalled? Any inkling into why this happened and what you gave up in doing this- as in top end or quickness or __? (the more angled ones give more top end or vice-versa?)

10. place the belt into the rear pulley and then assemble the rear pulley into the case.


I think I read this is a O/R specific belt and you don't have to get the kevlar belt? If I am wrong does it come with the new belt or does your "old" kevlar belt work with it?

edit- I see a title of one of your pics says "old vs new belt" so guessing a new belt comes with it, O/R specific?


I have more tuning to do once spring hits... but it definately felt like some grunt off the line... I think I'll have no issues with wheelies... even with the gears installed!

Gears? Have to install taller gears? Come with the kit or the ones you ordered before and able to use them again with the O/R?


Bottom line-

Does this mean the gears will give you top end and this O/R will make sure the lower end grunt is not taken away?


More ?????'s to follow I am sure...


CONGRATS DUDE!!!

(pics not working when I pull up the how-to)

[XPS1210]

okay.... MM, your killing me... all these questions! ROFLOL! (I figured out what that finally ment.... rolling on floor, laughing out loud! DUH!)...anyway...

Okay... the kit comes with 2 sets of rollers... 3.8 and I think 4.5g.... I put theg in first... and it stalled easy... variator comes out way to fast... so I changed them to the lighter ones and it didn't stall... you will still have tune the variator with the weights as it is litterally the same piece as the malossi multivar... (same part numbers...)


2nd...
the less angled slots on the rear pulley are suppsed to be for a quicker (bite) off the line... With mine stalling at first I went with the lesser angle slots... I'm guessing it's from me having the gears installed that I stalled... so I changed it to allow the RPM's to get higher before it kicked in the rear tire...

3rd...
The belt is specific to the over range kit.... it's longer (about 1/2 inch and thicker... a mm or 2 wider.. the stock replacement kevlar belt will not work!

4th... I installed the upgear kit from provo... These are not part of the kit but will work with the kit to get you a higher top speed... The gears make the engine work harder with the stock variator style set up and with the over range it allows a "lower" starting gearing to get off the line power that is lost from the gears... I personally recommend the gears... but if you don't get them... you'd have a monster wheelie machine!


yes... the gears is the top end... and the o/r makes more rpm's to allow for no loss on the low end and hopefully higher RPM's on the top end and a little more speed as well...

BTW the pics only work when you click on them... they don't show unless you click... I think it's a bandwidth saving feature! I'll ask king about it...

any other questions please ask... and I'll try and get a good answer for you...


~Jered~

[marylandmark]

Nice write up!

Thanks for the pic hint- after I typed my book above I tried that and it worked :)

Ok-

I think I got the jist of this thing...

It bridges the gap between trying to guess which combo of weights/springs and so on to use to get the best take off with the highest top end. You still have to play with the weights/springs and so on but sounds like a WINNER to me!

You can go with:

1. heavy weights in a "regular" variator=slower acceleration but higher top end

2. lighter weights in a "regular" variator=quicker acceleration but lower top end

3. O/R kit= still have to fine tune with weights but can install taller gears for a higher top end without losing the quicker acceleration. Best of both worlds- reach a higher top end quicker. (well maybe not higher top end than just gears without the O/R but won't take you all day to get there unless the O/R ~hopefully~ gives a few more RPM in the higher range which in turn will equal a higher top end..)


THANKS again for being the leader of the pack and getting this thing running!

[XPS1210]

yep... still keep the low end with installed gears...

Still have to tune the rollers and such...

But at the cost of about $350... Look around or ask provo for a good price... remember provo is pretty good about price matching!

[hybridrazz]

on the way to 65 jered.

[marylandmark]

Of course my "total package" is coming from Provo!

Erich was able to beat or match almost every price I found at those "other" scooter stores.

[XPS1210]

Just wanted to have you guys take note of this...

I edited the HOW TO on the install of the over range kit... as I over looked a part of the install... I screwed up and missed a MAJOR STEP!

So the deal is.... If you like electric start... this part isn't for you...

You need to disable the electric starter to operate the over range kit!

Here is the scoop...

After removing the old variator, you need to remove the 2 screws that hold the starter gear in place, take the gear off, all the washers there... as well as remove the gear from the shaft and all parts behind it...

I was looking tonight and didn't like how it looked like the belt was WAY to high up the variator... and sure as could be... it was not opened enough... around 2/5" not enough...

The kids were sleeping so I didn't get to test it but for a second... and HOLLY CRAP!!! talk about some off the line POWER! WOW! and I was happy with it the way it was... Definately a wheelie machine... I'll probably be changing the torque driver back to the recommended setting as I'm sure it will not bog now as it did before with the variator not being correct...

Also... with further inspection! The variator is not the same variator you get when you order the stock replacement one such as the technomoto... it's different... thus requires the removal of the starter gears from the tranny case... Also moves the belt much closer to the engine case and definately required the "shaving" of the fins in the tranny case!

So... bottom line, if you like your Electric start! This mod is not for you! I didn't know that when I ordered it as there was no info out on them... however lesson learned... but I can definately say it'll be Fun having this kit installed if the 2 seconds I ran it for are anything like how it will respond... I'll be on one wheel all the time! And without having much to pull back on! It'll be power wheelie baby!

Can you tell I'm happier now! YEAH! :cool:


here are a couple of pics that show how the crankshaft should look before installing the new variator... as well there is a pic of the stock clutch bell and teh winged bell... I highly recommend changing them as the stock one can blow up during use with the over range kit (according to Malossi)

[Lennox]

who needs and auto start anyway? My 105cc wont even turn over with the electric start! :eek: