Open CVT Cover for Kymco ZX50

[gsx600racer]

I started this project towards the end of this summer. My goal was to create a cover the would "box in" the CVT and simulate the original CVT cover in hopes of making as structurally strong as the stock cover(or better than no cover). I got side tracked a bit but got tired of looking at all the pieces on the bench

I started with a plexi template. I used this to locate and layout the locations of all the holes I had to cut out.

 





I drilled the outer bolt holes in the cover to size seeing I planed on not using the alignment bushings which would of stuck out more than the thickness of the diamond plate aluminum used.

I had some clearance issues with the intake and carb.







End result. The block that supports the other end of the bendix has a bushing pressed in just like in the original CVT cover.

[spaz12]

[oldgeek]

Pretty cool for sure, nice work!

[Jwhood]

Yeah that's bad ass bro!!

[ryan_ott]

Patent pending...

Great job!

[gsx600racer]

Thanks everyone, this is sorta part one of this project.

Unfortunately my PC hiccuped last night and its still scanning the drive for errors. All my drawings and renderings are on it. I am pretty sure it will be fine.

Anyways, here is a hint of what part two is going to consist of.(seeing I lost the kick starter)

[gsx600racer]

Dec 5, 2016 19:29:31 GMT -5 ryan_ott said:

Patent pending...

Great job!

Maybe. LOL

Nahh, I sorta stole the idea from the those that make the "Ankle Biter" setups for the Ruckus. They use a 2 plate system where mine is just one. The Kymco's belt runs on the inside of the trans and not the cover. The Ruckus's belt runs in the cover hence the 2 plate setup. 

Kymco Trans.



Ruckus setup.

[ryan_ott]

The pull start could be easier then you think. All the old stuff didn't recoil, just wrapped a cord around a v pulley with a notch in it. Doesn't seem too hard to fab up.

[gsx600racer]

Dec 5, 2016 21:05:05 GMT -5 ryan_ott said:

The pull start could be easier then you think. All the old stuff didn't recoil, just wrapped a cord around a v pulley with a notch in it. Doesn't seem too hard to fab up.

It will be a coil of rope with a handle stored somewhere. I have a pulley drawn up.

I thought of doing a recoil assembly, but I like the "old school" approach better.

[spaz12]

Dec 5, 2016 20:57:57 GMT -5 gsx600racer said:

Thanks everyone, this is sorta part one of this project.

Unfortunately my PC hiccuped last night and its still scanning the drive for errors. All my drawings and renderings are on it. I am pretty sure it will be fine.

Anyways, here is a hint of what part two is going to consist of.(seeing I lost the kick starter)

Pull start

[gsx600racer]

Dec 5, 2016 22:07:05 GMT -5 spaz12 said:

Dec 5, 2016 20:57:57 GMT -5 gsx600racer said:

Thanks everyone, this is sorta part one of this project.

Unfortunately my PC hiccuped last night and its still scanning the drive for errors. All my drawings and renderings are on it. I am pretty sure it will be fine.

Anyways, here is a hint of what part two is going to consist of.(seeing I lost the kick starter)

Pull start

Iv seen that vid. Thats one way to keep your acorns warm. 

[gsx600racer]

Here is what I have in mind for a pulley designs.

[greggkinney]

Would you be interesed in making one of these in thick plexi to sell?

[gsx600racer]

Dec 16, 2016 1:19:02 GMT -5 greggkinney said:

Would you be interesed in making one of these in thick plexi to sell?

Maybe waaaaaay down the road. I would really like to find a means to locate all the holes with more accuracy than using a plastic template. Iv had to tweak several of the holes to get things to fit and work better.

[greggkinney]

I got ya. Good luck with it and looking good!