Variator Install Problems

[zipgt5]

I got my new variator on my Zip gt5, it only came with one set of roller weights, and I think that they are to heavy becuase when i drove it, the engine wouldn't get above 5500 rpm. I went to take it apart to put the stock roller weights in and i got the crankshaft nut off, but I cant get the black bowl shaped nut off. Any advise on what to do to get it off or why it did that. It also made a weird noise when I started it was only at low idle, it sounded rough. Any help would be greatly appreciated.

[zipgt5]

does anyone know if it is the fact that my roller weights are too heavy and thats whats keeping my engine below 5500, or is it the clutch springs.

[speedy_scooter]

Its probably the weights. Try dropping them down a bit.

[str8dum]

5500 rpms? Thats barely even turning over. With 7g rollers in the stock Zuma vario, its revs 8000+ rpms.

I think your have another problem. But its cheap enough to try other rollers. You'll need about 5g rollers.

[zipgt5]

when i had the stock set up on it would rev over 9000. My variator kit only came with one set of roller weights, was i supposed to get more than that? Would my stock ones be worth trying?

[burnt_toast]

when i had the stock set up on it would rev over 9000. My variator kit only came with one set of roller weights, was i supposed to get more than that? Would my stock ones be worth trying?

if its the malossi vari, the weights that come with it are heavy as stuff! like 11g, don't use those. you'll have to get some new ones and they're not stock size, slightly bigger. in the time being stock would work though.

and best way for me to take vari off, without airtools: Buy a oil cap wrench that fits like 92-94mm and its perfect for fitting over vari face, then just spinning the nut with a wrench. Takes me about 5min to do a complete roller/belt change this way.

[zipgt5]

Ok thanks for the help ill have to order some 4.5 or 5, which would be better?
I'll try putting the stock ones in tonight.

The other problem I have is that my kickstarter gear seems to be stuck on, any reason why that would be or how i can get it off?

[str8dum]

malossi sends ot 11g rollers with their vario? Thats seems crazy. They rollers they sent with the OR were basically the correct weight (3.7g). I cant imagine any 50cc scooter that the MulitVar was designed for using 11g rollers.

Again, no 1st hand experience but that weight seems way off.

[burnt_toast]

malossi sends ot 11g rollers with their vario? Thats seems crazy. They rollers they sent with the OR were basically the correct weight (3.7g). I cant imagine any 50cc scooter that the MulitVar was designed for using 11g rollers.

Again, no 1st hand experience but that weight seems way off.

ur right it is way off, I'm not sure y but thats jsut what ships with the malossi. atleast back a yr ago or so when i ordered mine.

[burnt_toast]

Ok thanks for the help ill have to order some 4.5 or 5, which would be better?
I'll try putting the stock ones in tonight.

The other problem I have is that my kickstarter gear seems to be stuck on, any reason why that would be or how i can get it off?

this can lead ot serious problems later. best fix to prevent problems, pull your starter gear. just take it out. only do it if your starter and battery are good enough to start up each time. otherwise maybe lube up the kickstart gear and make sure it has no play. b/c once it hops over to the vari side you can have some trouble.

[zipgt5]

I got the kickstarter gear off and replaced the really heavy roller weights with the stock ones. It accelerates faster than stock, and gets up to like 43-44 on the flats. I talked to provo and they are sending me the rollers they forgot to send with my kit once i get those installed it should be even better!

One question I do have is that i have this kind of rattle at low idle, it goes away once i start driving. What could be causing this?

[str8dum]

the stock rollers are smaller than aftermarket ones

[zipgt5]

yeah thats why i put the stock ones back in, the aftermarket ones they gave me are way to heavy for the scooter.

Does anyone know what that low idle rattle would be from? Is that common on the malossi variators?

[str8dum]

the rattle is bc the stock rollers are smaller, so they rattle.