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General => Technical | How To => Topic started by: BettinANDlosing on June 18, 2014, 07:59:14 AM

Title: How to de-restrict 49cc variator
Post by: BettinANDlosing on June 18, 2014, 07:59:14 AM

Here is a little guide that will work for all Kymco 49cc scooters four stroke or two.
To complete this you will need an impact wrench or variator holder tool, and basic sockets.

First step is to take off the CVT cover, remove all of the 8mm bolts holding the cover on, if your model has a kick start it shouldn't change how to remove the cover.
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_001.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_001.jpg.html)

Once you have the cover off use an impact wrench to remove the variator nut (17mm). This nut is regular left hand threads on Kymcos.
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_010.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_010.jpg.html)

You can see the difference between the restricted Boss and Smooth boss.
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_006.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_006.jpg.html)

You can see how the belt has only been riding on 3/4 of the variator face not allowing top gear ratio.
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_007.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_007.jpg.html)

Put the smooth boss in and hand tighten variator nut
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_009.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_009.jpg.html)

Squeeze the belt with fingers then tighten nut with impact set on medium torque.
(http://i38.photobucket.com/albums/e148/zerosk8erfreak15/WP_20140617_011.jpg) (http://s38.photobucket.com/user/zerosk8erfreak15/media/WP_20140617_011.jpg.html)

Install all CVT cover bolts and there you go. Test drive and make sure everything feels normal, the only thing that should be affected is speed past 30mph will be much better. Good luck.