Stage 1 ????

[jpstrjohn]

Got my stage one to put on my 2005 Zuma. Installed the pipe, but can't make heads or tails out of the instructions for the varator. I know I need to change the weights to compensate for the new powerband, guess I thought this would be more matter of fact instead of guess work. I am 175lbs and mostly ride on the street. Any thoughts on a starting point? My Zuma ran about 35mph stock, and of course now with just the pipe it can't get rolling. Help!!!!

[XPS1210]

okay, there are about a dozen or so hex bolts to remove the tranny cover (they are under the black plastic cover), I think they are 5mm or 6mm hex... Take them out.. Simple but make sure you don't tear the gasket, it's easy to do...

Next take a pair of vise grips or a strap wrench if you can, and hang onto the finned pulley (if using the vise grips, tightly grab onto the kickstart washer), use a 17mm ratchet or wrench and remove the nut holding the variator togeather...

This will allow the variator to be removed, basically discard the old one ( I saved mine for emergency use) Install the new one as the old one comes off... Use the lightest weights to start with, set the into the pulley and take the 3 plastic sliders and hold them onto the plate... set the plate into the pulley on the guides... Once togeather, place onto the crankshaft threads, press it all the way in place and the you place the belt next (you will need to press the clutch end togeather with your hands to get the belt loose enough to get it in place in the front...

Now that the belt is on, installed the fillen pulley half and place kickstart washer back in and then nut... Tighten it down...

If you are going to install the springs in the clutch, then you need to hold off on installing the variator till the clutch is installed back in place.. Same story to get the clutch off, it's best to use a strap wrench but a pair of vise grips will work, lightly clamp from one of the holes in the clutch shoe to the out side, and use a 17mm socket or wrench... This will allow you to get the nut off... Once the nut it off, then you pull the shoe off, and the clutch will slide right off as well...

Use a 24mm ( I think I just use the vise grips again) and take the large nut off... I just took the vise grips and slammed the handle onto the ground till it finally let go... It's tight as hell! Once it loosed up I took the clutch and laid a knee on it... then took the nut all the way off... Then it all popped apart.

The little springs are a pain in the ass to get on, however they are pretty self explanitory... Use needle nose pliers to get them off and on... They are tight but I did it by myself! Once they are on, take the HUGE spring and place it where the little stock one came off... Press it back togeather and once again using your knee hold the clutch in place and thread teh nut back on... Once it's started take the vise grips and tighten the hell out of it...

Place the clutch back on the shaft, the the clutch shoe, then the nut... Tighten it back down via the method you used before to get it off... You need to squeeze the pulley face apart to place the belt as deep in there as you can, the install the variator as stated above...

It's pretty easy once you get the hang of it... I can change rollers in about 15 minutes now... If you need assistance futher please let me know exactly where your stuck and I'll do into further detail...

wear leather gloves, it'll save you some stitches! I bled for hours before my knuckle finally stopped bleeding and I swear you could see the bone.... It was gross!

[jpstrjohn]

Thanks for the details! I will definately were some gloves! I will give this proceedure a try this afternoon and see how it goes. Did you end up using the lightest springs in the kit? Did you get all the low end back with the spring change?

[XPS1210]

I actually used the delta clutch that Provo sells, I never messed with using the stock clutch for more than a day or so till I got the delta clutch... So I honestly can't remember...

I do know that I have the delta clutch as it came and the big rear spring installed with out and washers (part of the big spring kit in the variator)...

I have a little lag off the line but it kicks in good about 5 mph and pulls hard to the top speed! :D

[XPS1210]

oh yeah, Erich also has instructions posted on the provoscooter.com howto's If you need additional help and I'm not online, take a look there... He has good info there! :o

[zumanator]

try to get an impact wrench, it saves time and knuckles :p
also torque wrench and strap wrench are worth the price.
erik has torque spec's .

[jpstrjohn]

Well, everything went together. Replaced the varator and used the light weights, the silver ones. Put the new clutch springs on and the BIG spring in the clutch. Still, had no low end!!!! Put the stock pipe back on and everything was good again. Do I need to wait until the 70cc and carb upgrade before this pipe and trans mods will work and be worth while? It seems that I give up all the low end with the pipe.

[XPS1210]

unfortunately I staged 1-3 all at the same time...

Anyone?

[zumanator]

stage 1 will be slower up to 10 mph than the pipe kicks in.
mid range and top end are much better, 45mph to 50mph
depending on your wght. buying gps to check for sure.
you might have to play with rollers and clutch springs to
get the right balance for your setup.

[jpstrjohn]

Yeah, I can can peg the speedo if I am on a flat surface, but I am giving up WAY TO MUCH on the low end with just the stage 1. The pipe kills all the low end no matter what weight combo I try! I think it definately needs the 70cc to give it the grunt back before I put the stage 1 back on. Thanks for the feedback. I have an advantage too, my wife has a Zuma also, and we are leaving that one stock for now, sort of as a test mule. I know once I get mine staged up she will be hooked!

[Zuma_Man]

hey, jered, anyone, k, in about an hour i'm going to de-restrict my '05 zuma, my friend is going to help me as he has owned 2 scooters in the past and de-restricted them. He only has one concern, about the restrictor in the pulley on how to go about removing it. any advice would be great!

[Lennox]

http://www.provoscooter.com/shop/howtovar.php this is the link to the vari dereg.... hope it helps