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Post by bigdeal on Jun 26, 2019 15:50:07 GMT -5
Recently done a complete rebuild, 70cc Stage 6 MK II engine package. Doppler crankshaft, Polini high speed variatior. Rejet carb to 102 and it fires right up and runs just fine with no belt, as soon as I put the belt on it starts and runs for 3 seconds and stalls dead and the belt is tight and won’t turn. Still using original starter and starter clutch. I’ve tried with both with and without shim and results same. Too tight to turn variator by hand, clutch side spins free.
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Post by ryan_ott on Jun 26, 2019 16:43:36 GMT -5
You may want to take another look at the spacers behind the variator and the alignment in relation to the rear pulley. I needed a decent amount of shimming to get mine to work properly.
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Post by bigdeal on Jun 26, 2019 19:58:27 GMT -5
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Post by ryan_ott on Jun 26, 2019 21:07:36 GMT -5
I think you have too many shims/washers or they are in the wrong location. I think when you are tightening everything up your pushing the starter clutch into the case. Pull it apart and look for rub marks to see what is rubbing and where. I have about 5mm worth of shims behind my variator and the original spacer.
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Post by bigdeal on Jun 26, 2019 21:08:22 GMT -5
0 shims
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Post by ryan_ott on Jun 26, 2019 21:19:20 GMT -5
Do you have the original spacer on the crank first, then starter clutch? That is where I’m thinking the contact is. Compare the Polini variator boss length to the OEM one and see if there is a difference in length. If there is you may need that much worth of spacer or just swap the boss if you can.
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Post by bigdeal on Jun 26, 2019 23:18:54 GMT -5
Yup, just like the YouTube guy I was missing the spacer before the starter clutch and my service manual doesn’t show it. Thank you, it’s working amazing now!
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Post by ryan_ott on Jun 27, 2019 10:30:02 GMT -5
If you ever ditch the electric start parts for kick start only you will still need that spacer and enough shims to make up for the thickness of the starter clutch, about 5-6mm.
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