Powerlink Install Gone Wrong

[90GTVert]

I've seen plenty of people say that Gates Powerlink belst are nice belts. I've always used standard belts and never tried a Gates or other premium belt, but I decided to finally try one out.

My old belt measured 15.2mm wide, and the service limit is 15mm. The new Gates belt measures 17.4mm wide, spec'd at 17mm. Most 17mm spec belts end up around 16mm new according to my measurements. This belt seems a bit wide and won't travel all the way down in the vari. I figured I'd try it out anyway.



It bogged taking off but started picking up speed and acting closer to normal. I made it about 3/4 mile and heard a noise coming form the CVT. I stopped and turned around. As soon as I hit the throttle to take off back to my house there was more noise and it free-revved. Oh boy. I pushed it home.

When I pulled thje CVT cover off, these parts fell out.


The nut had came off of the crankshaft and half of the variator fell off. It stripped the fins off of my variator's outer face, warped the star washer, and the starter pawl is missing.


I also found that the nut and threads on the crank were damaged. There isn't much depth left to the cranks threads.


I'm going to have to tap the crank and use a different size nut to salvage it. I don't really wanna spend the time and money on a new crankshaft and all the related expenses right now... plus I'd like to keep this thing on the road as much as I can while the weather is still good for riding.

I started grinding the crank a little to get a 7/16"-20 tap to start. I quit pretty quick tonight. I just don;t feel like doing it now, and I'd rather feel like doing it right since it means replacing the crank if I screw it up.


I think the threads have been slowly suffering because I've done so much CVT tuning on this scoot. I use an impact gun to remove and install the vari nut. I'm going to look for a torque stick or torque socket that's 30-45ft-lbs, the specified tq for this nut. I've tried holding the vari with a vari tool before, but it just breaks fins. I guess I could take other side of the engine apart every time I mess with the CVT to hold the flywheel.

[2strokd]

Darn it , i hate it when that happens. The same thing happened to me when i tightened my vari up on my belt. I only made it about a half mile when i heard what sounded like a metal pole being shoved into a wood chipper . Thankfully i was only going about 20mph when it happened to me, so i was able to stop before it got that bad. Sorry to hear the bad news bud.
Hope you can get it fixed up with out having to put in a crank

[90GTVert]

Yeah, I hope so too. I've got another crankshaft here, but it's 45mm stroke. I'd need 43mm stroke to use without needing any machining or cylinder adjustments. If it were just a straight install, it wouldn't be so bad. I could probably use a bearing replacement anyway, but the money adds up quick replacing the vari, vari face, rollers, fasteners, bearings, machine work and/or different crankshaft, gaskets, etc....

My stock 49cc crank was actually threaded to 7/16"-14 I think it is. Same deal. It's a pain. The crank and all materials on these scoots seem so cheap until you are trying to get a die over 'em.

I ordered a 30ft-lb torque stick last night. I'd rather go 40, but I can't seem to find 35 or 40ft-lb sticks. I could buy 65-150ft/lb sticks at 1,000,000 places since they're common use lug nuts.

[90GTVert]

While looking around for transmission parts at an ATV site, I found a 45mm crankshaft that claims to be a "direct replacement" for the 43mm crankshaft stock in ATV's... which is the same as mine. That would push the engine to about 103cc with a 54mm cylinder. It's not bad at $95. I'm not gonna do that now, but if something screws up, or whenever this motor needs a complete overhaul, I may have found my new crank. I'm going to contact the place to see if it's truly a driect fit with no machining or if it's just got the right size splines etc...

www.kaseaparts.com/45mm-crankshaft-assembly-p-1595.html

This would be fun too lol...
www.kaseaparts.com/sh90-reverse-kit-p-1596.html

[90GTVert]

I worked the crankshaft with a grinder a little more, until it was the proper size for a 7/16"-20 die.


I used my spanner wrench, which I tend to call a variator tool, to hold the flywheel still while I cranked away on the die.


Tada!


I was quite happy to see these fresh new threads. ;D Now I just need to pick up some 7/16"-20 nuts and wait for my other parts to arrive.

I mentioned the variator being damaged from using it without dampers (they disappeared on me) in another thread. I never got pics then, so while it was out I figured I'd show you what running without dampers will do to a variator.

[stepthrutuner]

Glad you got it resized. I probably would have cobbled some of those dampers from some scrap nylon or something. Funny that they went missing.

[90GTVert]

A customer was using the exact same variator and his dampers were missing. It wouldn't be a big deal if I could get replacements. You can tell when the dampers are gone because you'll get a real loud metallic ticking sound at idle, I would assume from the back plate and vari bouncing off of each other. I'm giving it one more shot, I probably shouldn't... but this $50 variator has worked out very well... other than the damper thing.

Just another tip while I'm here. If anyone else has this trouble, you might wanna pick up half nuts instead of standard nuts for the crankshaft. Half nuts are what the factory uses. I don't think a whole nut will even thread all the way on. I got both just to have options.

Sorry, my camera sucks at up close pics, but you should get the idea.

[2strokd]

Looking good! Sure am glad you got the crank threaded.
I had to do some spacing tricks to be able to use my kickstarter after i modded my vari and shaved my drive boss down. I had to put a homemade washer in front of the vari face so it would tighten the vari up all the way, ran outta threads w/out it. I know you dont use your kick to start anymore, but anyone that is might not be able to with a standard nut.

[90GTVert]

I got most of the parts in yesterday, and the rest today.


I installed the new parts and the Powerlink belt. The belt is too wide and this as as far up in the rear pulley that the belt can travel, even with a spacer in the vari. The Powerlink that I orderd as 788 17 28 is simpy marked 788 18.1. It measures over 17mm and a 17mm spec belt is usually around 16mm new.


I went back to my old belt which is just above the service limit.


It's back on the road again, but I still need a new belt that will actually work. I wonder if all Powerlink belts are 18.1 or if the seller just wanted to get rid of 'em so they were labeled different?

[2strokd]

Cool your on the road again ;D! Is that the same type of vari you had in before? That sucks that your belt wont work . Wonder why they even both tagging them with a size if they arent that size . Mine wasnt the size the belt said it was either, closer than yours but i wouldnt recomend the belt im using because it started to fray after the fist ride

[90GTVert]

That's the exact same vari I had before. Got it from Parts For Scooters. I know I can order a Bando and get the right size, that's what I usually do. The Powerlink actually looked like a littel better belt, so if I knew I could get it in the exact size I'd try again.

[2strokd]

My bando is allot stiffer than the whatever it was i got from autotech, but i agree, i think i will stick with what i know works and is the size it says it is...

[2strokd]

One of those vari,s dosnt sound bad for the price...Longer ramps? Diff angles? I cant remember if you said with all the builds im reading about lol.

[90GTVert]

Teah, it;s got longer ramps and all that fun stuff. It's a Malossi clone.

[2strokd]

Ohh no i remember. Hmm, maybe one of those after a carb?