Comparison pics and info. Seems to me that just looking this stuff over might be helpful for ppl to get a better idea of how some of this stuff works.
To keep things simple, I arranged all of the front pulley parts in this order in these pics. From left to right : Stock, Hoca, Malossi OR.
Here are the three movable halves side by side. The Hoca variator shown in the center is a very common Malossi Multivar clone. They work very well as an affordable CVT upgrade and you can keep the electric starting system, unlike over range variators. The outside diameters are 95mm, 97mm, and 99.5mm. A larger front pulley can potentially create better high speed gearing, assuming the belt is capable of traveling to it's outer edges.

These pics show the assembled variator from the side as well as different angles of the ramp plates. It's easy to see the extra thickness of the over range variator. The additional size is the reason for needing to remove the electric starter components. Of course it has it's benefit, extended travel. Look at the longer guides that stick out the rear of the over range variator. They let the ramp plate and movable half move farther apart, without becoming separated. This is a key feature of the overrange variator.




These pics show the back side of the movable halves. You can see that both aftermarket variators change up the layout of the 6 ramps that the rollers ride in. The stock piece lays them out as 3 sets of 2 ramps close together. Both the Hoca and the overrange space all of the ramps evenly. The aftermarket parts look like they would be better balanced and allow the rollers to apply a more even force to all areas.


Here are some close-up pics of each. You should notice other changes to the ramp layouts, other than just spacing/positioning. They all use different angles and lengths within the ramps and ramp plates (shown earlier) to create different characteristics. The pics are ordered, stock, Hoca, Malossi.



These pics show a crucial area of the ramps to get the most travel and speed out of a variator. The outermost end of the ramps. Look at the stock variator and how it ends the ramps short of reaching it's rear edge. Now look at the two aftermarket variators below it. They both continue the curve of the ramps all the way out to their edges to encourage max travel.



Here are more views of how the ramps are setup for more length in the aftermarket parts.



Here are a couple of views of the roller weights that each variator uses. The stock variator uses 15x12mm rollers. Hoca uses 16x13mm rollers. Malossi OR uses 19x15.5mm rollers. The larger rollers help enable the variator to have more travel.


Here are the drive bosses for each variator. It's not hard to see a difference in length among the three. Stock measures just over 38mm long, the Hoca is 37mm, and the Malossi is 45mm. I almost always end up adding a spacer washer using the Hoca variator to give a bit more room for the belt to reach the center of the pulley.

In this view of the drive bosses, you may notice a difference in outside diameter in the stock vs the aftermarket parts. Stock is 21mm OD and the others are 20mm OD. It's not much, but every little bit helps. The smaller the drive boss, the farther you can get the belt toward the center of the front pulley for a better "1st gear" as some of us call it.

Now I'll move on to the fixed half of the front pulley. For these left to right is : stock, Stage6, Malossi OR. Stock has an OD of 95mm, the Stage 6 actually decreases from stock to 93mm, and the Malossi is 97mm.

In the pic below, I've put the Stage6 drive face on top of a couple of pens to level it out for easier comparison, since it has no fan blades like the others. They all seem to have similar angles. The main difference I see is that the stocker has a much larger flat area in the center. The ones that keep their angle closer to the center usually perform better for initial takeoff when the belt is riding low in front.

The front pulley should be covered pretty well, so let's look at the rear pulley / torque driver. Pictured on the left is stock and the right is the Malossi OR. I have Hoca rear pulleys around, but they measure out the same as the stock setup pretty much, only with a straight grooved torque driver like the Malossi instead of the stock dual-angle. If you aren't clear what this means, there are pics farther down. There's an obvious difference in outside diameter in stock and the OR here. Stock is 115mm and the over range is 128.5mm. While a larger front pulley allows for better high speed gearing, a larger rear pulley can provide better low speed gearing for stronger launches. This assumes the belt is able to reach it's outer limits.

On top of just being larger overall, the over range pulley seems to be designed to make full use of it's diameter. In the top pic you can see that the stock pulley rounds out, where the Malossi pulley is flat all the way to it's edge. This should make for even more usable area.


Here you can see both rear pulleys in their fully closed (top) and open (bottom) positions. The stock pulley leaves 15mm at it's outer edge when closed, while the OR pulley has 16mm of clearance there. When fully open, stock has 26.5mm between it's two halves at the outer edge, and the overrange has 30.5mm there. Stock moves a total of 11.5mm in it's full range. The over range moves 14.5mm.


One thing to pay attention to if you get an over range torque driver is this cover, and specifically how it works with your torque spring. The Malossi uses a cover that's 1.5mm larger in diameter than stock (45mm compared to 43.5mm). This can cause some standard springs for the minarelli to bind. Ideally, the spring should be able to rotate relatively freely. Some companies, such as Kombat, offer springs specifically for the OR pulleys with a bit larger ID to fit better. Springs for the GY6 50cc / Honda Dio may also work with the OR pulley.

If you look under that torque driver cover / spring locating plate (which you will have to because the Malossi OR rear pulley comes without pins, grease, and o-rings installed), you'll see another difference. The stock torque driver (left) has a dual-angle groove or path. The Malossi, and most other performance torque drivers, has a single angle path. It uses 2 sets of these paths that are cut at different angles to fine tune your CVT. The straight paths allow for very linear performance. The dual-angle paths can be excellent for your average street scooter though. They start off at an angle that allows them to get the revs up easily, then transition to a different angle at speed to keep RPM lower for cruising. Great for streetability, not great for all out performance.


