Vari back plate stuck

[t-bone]

I have had my new malossi off and one a couple of times over the last week trying rollers and spacers. I took the pulley off today and now the angled plate won't come off. I've tried pulling back and forth gently on the sides, hard on the sides, everything. I've greased the shaft. The plate will only come forward about 1/4-1/2 inch and then just stops. It gets too tight around the shaft to move any further. I can't see any obvious reason for this other than it all of a sudden acts like the shaft is too small. It went off and on numerous times without problems. This is killing me.. what is going on?

http://tenbox2.cascss.unt.edu/vari.jpg

[str8dum]

the splines on the crank must be buggered, esp if the back plate moves and then gets hung up. you are in quite a pickle now. Good chance that the crank is ruined.

Not much you can do except to keep tryin to wiggle the plate. In the end you'll most likely need a new vario and crank.

[t-bone]

Thanks for the response. I can't imagine that its buggered or what would have buggered it. I've ran about 10 miles with it is all. I can't see any sign of buggergedness when I look all the way around it. If it is really the crank then I must have really done something wrong and I don't think I have.

[pinkymingeo]

How's about you take a big screwdriver and pry it off. If the vario isn't properly torqued, the plate can get jammed. Maybe the teeth on the plate, maybe the splines.

[str8dum]

yeah hopefully its the splines on the back plate. If thats the case, you';ll just prolly be out a vario. No biggie.

[xraydino]

This might sound retarded but, if he can lean the bike enough do you think the other piece can be manipulated on with out spilling the rollers?

[Zuma-Zuma]

Take a sharp edge pick, or a fine, triangle file, and run it up and down each groove on the shaft. Do this all the way around, until you've "cleaned" every spline. Then, feel with your fingers the outer points of the splines, and feel for any imperfections. If there are any, use the file again, and gently clean them down. Don't rock the plate anymore, as this WILL screw up the plate, and will put divits on the splines. If the plate moves at all on the shaft, this will work to get it off.

[VeniceRocket]

Ummmm I feel dumb but it happened to me and i hit it left to right and it was merely orqued to mucch to one side and i hit it back GENTLY wit a rubber mallet and it released and came off.

Just a thought it might not be that but it sounds like what happened to me i had it off and on like 12 time just "troubleshooting" the weights.

[t-bone]

Thanks for all the suggestions people. I will report back.

[t-bone]

I got it off by prying and working it around the one tight spot. I reinstalled it with a spacer between it and the starter clutch. I tried mixing 3 white 5 gram ( I think) weights and 3 black Malossi 7 gram weights. This is the perfect combo for me and I now have wonderful acceleration all through the powerband! woohoo!

[zumasterling]

I'm with zuma-zuma, I have bought bikes from auctions with far worse damage than that to the guts of em and saved darn near all of it. One of my other mottos: It's never that F'n bad.