Kymco People 50 2-stroke variator and starter ratchet removal problem.

[garicao]

Hi, I have a problem/question with my 2-stroke People 50.

1. I need to take the variator off and it won’t budge. The 19mm nut came off without problem, but the variator won’t slide out despite a good puller. Any ideas?

2. The kickstart ratchet looks like it doesn’t need to be removed from the variator for variator removal. Is this correct?

3. However I want to take it off since some previous owner installed the plastic fan wrong. Given the direction of its teeth, I’d think it should have reverse (clockwise to remove) threads. Anyone know?

Thanks for your help.

--garcia

“We’re lost, but we’re making good time.”

[garicao]

Minor corrections: The part I can't get off is the drive pulley face; variator's behind it. The drive pulley nut is 12mm and uses a 19mm socket, as i recall.

--garcia

[garicao]

Update: One problem solved, new one found.

The ratchet kick starter was not coming off because it was rusted hard onto its splined shaft. Penetrating oil plus heat and percussive maintenance finally got it off. However the variator face drive, directly behind the ratchet kick starter won’t slide over the same splined shaft. Anyone know if the face drive center hole is spozed to be splined? If so, its splines are rusted and rounded and I’ll probably have to cut it off...unless someone has a better idea.

ciao,

--garcia


“Hey! Where are we going? And why are we in this handbasket?”

[garicao]

Well, splines on the drive shaft were buggered and there’s a 5mm wide gap where there are no splines at all. The outer belt-drive face was found in the non-splined gap in between with all its splines also worn off, held in place only by the output shaft nut. I’m guessing that this mess was caused by the outer belt-drive face slipping on the shaft and carving a groove on the shaft.

I eventually managed to pry it off the output shaft, but the variator (with stock boss length) and inner belt face drive take up all of the inner splined length. Since the replacement outer belt-drive face won’t reach the inner splines, I shimmed behind the variator so that the outer belt-drive face can’t slide past the outer splines and into the gap. Don’t know if this is right, but it’s all I could come up with and seems to be working.

That's all...for the moment.

Thanx for reading.