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Post by niz76 on Feb 16, 2015 19:19:19 GMT -5
Watching this thread with interest!  |
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Post by oldgeek on Feb 17, 2015 0:11:53 GMT -5
Does anyone know where to pick up a Variator boss for the BWS 100? It should be 43 long x 21 OD x 16 ID. I see there is one on ebay, but I would like to find one somewhere else. How about an OEM part number.
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Post by 90GTVert on Feb 17, 2015 9:09:17 GMT -5
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Post by oldgeek on Feb 17, 2015 13:12:03 GMT -5
Thanks, I went ahead and ordered the one from ebay. I guess it will be here in a week or two. The rear pulley fits perfectly, and has a larger diameter than stock, but smaller diameter than the Malossi OR pulley. I will post pictures and measurements as soon as I get a chance. The variator is another story. It is HUGE compared to the stock variator, and also larger than the Malossi. The outer pulley measures 110mm diameter and the inner pulley measures 108mm. There is no way the BWS outer pulley will fit under the CVT cover without modifying either the cover, pulley or both. As you can see in the pictures, the inner pulley just fits in the case. I took the start components off, but did not remove the starter boss from the case because there may be no need to remove it. I used a spacer and washers to make a 10mm spacer to go behind the ramp plate. The 10mm spacer creates plenty of clearance for the inner pulley, and it looks like the belt lines up pretty well. I did some checking, and it seems that the BWS 100 variator will not need to use all of the outer pulley, that is why you see a HOCA outer pulley in the second picture. All of this is just a guess for now, I will have to wait until the correct variator boss gets here to do any testing. More to come later as I get time to work on this project.     |
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Post by 190mech on Feb 18, 2015 10:13:50 GMT -5
I wedged a GY6-150 variator under 'Snoopy's' CVT cover,it required a bunch of machine work and the kick start had to go,cover had to be chopped up a lot too..
I think the BWS sleeve will be 6mm too long as its crank is that way,It'll all likely work out with much thought and metal chips flying!!
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Post by oldgeek on Feb 18, 2015 12:38:50 GMT -5
If my measurements and mockup are close, the 43mm boss will be ok, but I will have to make a 10mm spacer for the back of the ramp plate. The belt alignment looked ok, but I guess you never really know until you get the actual parts in your hands and bolted up.
There is no way the bws 100 outer pulley half will fit without major mods to the cvt cover. I cant screw up the kick start, so I will likely try to use the hoca stock style outer pulley instead of the bws 100 outer pulley.
Sent from my SGH-T999 using proboards
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Post by Lucass2T on Feb 18, 2015 13:56:58 GMT -5
Those variators look more like piaggio variators than minarelli variators, did i miss something?
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Post by 2strokd on Feb 18, 2015 14:05:16 GMT -5
From what ive seen most the bigger, or OR Minarelli stuff does end up looking like stock Piaggio 49cc stuff.
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Post by oldgeek on Feb 18, 2015 15:36:18 GMT -5
Those variators look more like piaggio variators than minarelli variators, did i miss something? Sorry I left out some info as usual! The variator on the left is a performance variator meant to replace a stock bws 100 variator. The variator on the right is a malossi OR variator for a standard horizontal minarelli Sent from my SGH-T999 using proboards |
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Post by oldgeek on Feb 21, 2015 9:21:22 GMT -5
Well Instead of waiting for a bushing to come from who knows where, 190Mech informed that a STOCK 49cc CPI minarelli bushing has the 21mmx16mm dimensions I need. I feel even dumber than normal now because I have several of those laying around, somewhere.
If the weather holds up around here, I will be testing this setup out on the 99cc build today and tomorrow.
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Post by 90GTVert on Feb 21, 2015 9:52:00 GMT -5
Sorry, I figured you knew that and just wanted to get a longer drive boss instead of trying spacing with a standard stocker. Hope the testing goes well!
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Post by oldgeek on Feb 21, 2015 12:57:14 GMT -5
Sorry, I figured you knew that and just wanted to get a longer drive boss instead of trying spacing with a standard stocker. Hope the testing goes well! It's alright! I have been using the Hoca variators which use a 20mm bushing for so long that I didn't even think to check a stock bushing. I had to do some digging to even find one that was not rust covered. I am trying to get the original setup back up to 57 mph, but the cold and light rain is fighting me. I had it up to 53mph @9500 rpm using 6 gram sliders, so I changed to a mix of 5 & 6 gram sliders and it slowed down to 50mph @9100 rpm. Exactly opposite of what I thought it would do. I will work with the original setup for a while longer, but I am itching to get started with the OR stuff.  |
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Post by oldgeek on Feb 21, 2015 22:11:25 GMT -5
Light rain most of the day, so test rides were short. I managed to get the original setup to 53mph, and decided that was good enough. I pulled all the original CVT parts and estart off, and started fitting the BWS 100 parts. I made a 10mm spacer to go behind the ramp plate, and added shims to the variator boss to get it to the 43mm length I needed. I used the Hoca fixed half pulley and a malossi 6111108 belt. I fired it up on the center stand, then unbolted the CVT cover and took it off to have a look while it was running. Revving it a bit I quickly found that the belt was going to travel a lot further than I thought it would on the front pulley, so the Hoca drive face was not going to work. I spent several hours modding a spare CVT cover to get the BWS fixed half pulley to fit underneath the CVT cover, and also ended up trimming the BWS pulley fan blades in order to make it all fit with the CVT cover on. I added some support straps to the CVT cover to hopefully strengthen the kicker portion. It looks like krap but at least I can start it.    By the time I finished putting it together, it was dark and misting rain again, but I decided to take it for a spin anyway! I immediately noticed I had a better low gear, and acceleration was better. I rode it around the warehouse a bit and everything seemed good, so I took it down the road. Everything was fine until I got up to 40mph, and I could feel something dragging so I backed off and everything went back to normal. I sped back up and the same thing happened at 40mph. I did it a couple more times, and took it back to the warehouse. I am pretty sure the belt was rubbing the inside of the CVT cover when the variator closed enough. I could see a faint line on the center of the belt through the slit in the CVT cover. I may be able to get a bit more clearance inside the CVT cover so the belt might not rub it, but I wont know for sure until I can mess with it more tomorrow. I think the malossi belt may be just a tad too long, but I don't know for sure. I welcome any suggestions anyone may have. |
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Post by oldgeek on Feb 22, 2015 21:36:47 GMT -5
Worked pretty much all day on the scoot. It rained on and off all day again. I pulled the CVT cover off first thing to see what was causing the drag as soon as I hit 40 mph last night. I found it was actually the moveable variator pulley hitting the CVT cover when it closed.  A trip to the band saw and a minute with the burr grinder fixed that problem. The rest of the day was spent trying various setups. The best I could pull out of the setup so far is 55.92mph @ 8700RPM. I had problems getting the RPM up to where they were with the original CVT. Here are most of the setups I tried, pretty much in the order I tried them. White Malossi contra spring, stock style groove/6x10 rollers = 60 grams/7000rpm @ 50.45 mph White Malossi contra spring, stock style groove/6x9 rollers = 54 grams/8400rpm @ 54.8 mph White Malossi contra spring, stock style groove/3x10 & 3x5.5 rollers = 46.5 grams/8400rpm @ 54.8 mph Yellow 1500 contra spring from autotech, stock style groove/3x9 & 3x5.5 rollers = 43.5 grams/8700rpm @ 55.92 mph Yellow 1500 contra spring from autotech, steep groove/6x5.5 rollers = 33 grams/9400rpm @ 50.9 mph Yellow 1500 contra spring from autotech, middle groove/3x5.5 & 3x7.5 rollers = 39 grams/9000rpm @ 53.13 mph White Malossi contra spring, middle groove/3x5.5 & 3x7.5 rollers = 31.5 grams/8800rpm @ 53.7 mph Yellow 1500 contra spring from autotech, middle groove/3x5 & 3x9 rollers = 42 grams/ RPM?? @ 55 - 57.5 mph 1500 Short contra spring on a ball bearing base, steepest groove/3x5.5 & 3x10 rollers = 46.5 grams/9K @ 58.16 Strange results on some of the setups IMO. Also I have at least 4mm on the variator that is unused when it is fully closed. Will a wider belt help? The specs for the Malossi 6111108 belt I am using is 816 x 17.5 x 30 They have a 818 x 18 x 30 belt (6113191) but I would hate to buy a $40 belt if it does not help. Comments are always welcome. |
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Post by 90GTVert on Feb 22, 2015 23:06:39 GMT -5
Strange results on some of the setups IMO. Also I have at least 4mm on the variator that is unused when it is fully closed. Will a wider belt help? The specs for the Malossi 6111108 belt I am using is 816 x 17.5 x 30 They have a 818 x 18 x 30 belt (6113191) but I would hate to buy a $40 belt if it does not help. Put the two halves of the front pulley together and measure the gap near the outer edges or just kinda "test fit" the belt you're using in there to see if it even could be squeezed that far up. Thanks for all of the details! |
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