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Variator Installation

These mods may void your warranty and are not for the technically challenged. Provoscooter takes no responsibility for any undesired effects and or results that may come about in performing these modifications. With that said we have taken care to provide the most verbose (illustrations and text) available for the Vino and Zuma. These modifications are specifically for the Vino/Jog, but may serve as a reference for many other scooters, especially those with a minerelli motor. NOT FOR STREET USE. FOR RACE USE ONLY. ;-)

These are the tools needed for this modification:
17mm Socket and Impact Wrench, or Ratchet and Strap Wrench

 

Have you ever bought something that you are very excited about, you get home, tear into the box, pull all the parts out, stare at it for a little while, then take a look at the instructions, and with a very painful drop in your stomach, realize they are in another language? Well that has been the case for our customers that have purchased an aftermarket variator. To help, we have provided this handy guide on installation and identification to allow some smoother installs. Enjoy.

There are several parts to the variator as listed below.

At left you will see the variator with backplate installed with rollers underneath and sliding "vee" bushings in place. With the steel crankshaft sleeve in place on the opposite side, it is ready to be installed on the crankshaft.

Above is the variator with roller weights in place. For tuning all bikes should start with the silver color roller inserts. For Vinos these usually work well. For the Zuma and other bikes, you may need some lighter weights available on this site. The weights dictate how fast the bike "shifts" into higher gear. This is important when you start out from a stop as you want the bike to rev up to power band (the rpm range that the motor produces optimal power) before it starts to "shift" or vary the transmission. If it shifts too soon, the bike will not perform well.

At left is the front side of the variator. With the backplate and rollers in place on the underside, it is ready to install on the crankshaft.

Below is the whole assembly (without rollers) and the order of installation. The steel sleeve goes into the variator and rests on the backplate when fully assembled (as above). The thin washer at far right goes directly after the steel sleeve, and before the finned pulley half from the stock setup. (For info on the stock variator, see the Variator Deregulation how-to).

This is the backplate with sliding vee bushings in place. They take up most of the centrifugal power from the motor and relieving the rollers of some of the torque. They are a serviceable part, and replacements are available on this site.

This ginormous spring is the torque driver spring. Installed in the rear clutch assembly, it forces the rear pulley halves apart as the rollers are retracting back into position when engine speed decreases. If your belt is not retracting at lower speeds (if you slow down from a higher speed to a lower speed, then hit the throttle and it does not recover or speed back up as quick as expected you may need a stronger spring, or just a shim - see below). For instructions on how to install, please see Stage One Install.

At left are the ring shims for the torque driver spring. Normally for the minerelli, these are not needed.

At right is the assembly for the rollers. The Tecnomoto Variator comes with three different weights, but usually the silver are the ones used. The plastic caps are placed over the steel weights and put in the variator. These are a serviceable part and replacements are available on this site.