HOW TO CLEAN A CONTINUOUSLY

VARIABLE TRANSMISSION (CVT)

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Introduction
Scooters, like any other vehicle, require regular maintenance to remain in good, working condition for as long
as possible. Cleaning the continuously variable transmission (CVT) is required to keep the scooter running
properly. If the procedure is not completed every three to four months, the CVT could become clogged with
dirt and grime. A clogged CVT could keep the scooter from working properly, or at all. Any scooter owner
who wishes to maintain the quality of life for their scooter, should use the following guide to clean the
scooters continuously variable transmission.
The following guide will show how to remove, clean, and replace a continuously variable transmission. The
process is quick, easy, and only requires a few tools. The procedure can be completed wherever there are
tools. A garage is the simpler location choice, but there are no harmful or staining fluids involved in cleaning
a CVT, so the procedure may be performed in any desired location with room enough to reach the scooters
CVT parts.
The CVT cleaning process involves many loose parts, bolts, and screws. Designate a safe place for loose part
storage when removing the CVT components. Ensure the loose parts are not lost or mixed up, to prevent any
mishaps when replacing the CVT components.

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What You Will Need

(a) Phillips Screwdriver
(b) 8mm Socket Wrench
(c) 10mm Box End Wrench
(d) Impact Gun (or Strap Wrench)
(e) 14mm / 17mm Socket Attachments

NOTICE

Using anything other than an impact gun

or strap wrench will damage the CVT
components.

Items not pictured:

(f) Paper Towels or Rag

Step 1: Remove Kick Start Lever

i.

Unscrew bolt on kick start lever with a 10mm

box end wrench.

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Step 2: Remove Air Box, if necessary*

*This particular scooters air box partially overlaps
the CVT cover. The air box must be removed before
attempting to remove the CVT cover. If your
scooters air box does not interfere with the removal
of the CVT cover, skip to step 4.
i.

Unscrew all four screws attaching the air box

to the scooter, using a Phillips screwdriver.

ii.

Place screws in a safe area to prevent losing

any.

iii.

Pull air box from the scooter and set aside.

Step 3: Remove CVT Cover

i.

Place 8mm socket wrench on bolt in a

horizontal position.

ii.

Rotate socket wrench approximately 90o

counterclockwise, just to loosen the bolt.

NOTICE

Loosen all bolts before removing the

bolts entirely. If bolts are removed
individually, the CVT cover may crack or
warp.

iii.

Repeat steps i and ii for each bolt.

iv.

After all bolts are loosened, completely

remove bolts with the 8mm socket wrench.

v.

Set bolts aside.

vi.

Pull off CVT cover and set aside.

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Step 4: Remove Front and Rear Pulley

NOTICE

Tap the impact gun trigger when

removing bolts. Holding the impact gun
trigger will cause damage to bolts and
other nearby components.

i.

Remove front pulley bolt with impact gun and

17mm socket attachment.

ii.

Set bolt aside.

iii.

Grip rear pulley with one hand to prevent

spinning while using the impact gun.

iv.

Remove rear pulley bolt with impact gun and

14mm socket attachment.

v.

Set bolt aside.

vi.

Remove the front and rear pulley

simultaneously (belt will come out with the
pulleys).

Small hardware (e.g. bolts, washers,

screws) may fall from front pulley, upon
removal of pulley. Collect small hardware
and set aside for reassembly, later.

vii.

Wipe all surfaces of pulleys and CVT with

rag or paper towels to remove any dirt or
debris.

NOTICE

Do not use liquids to clean CVT or its

components. Liquids will damage the
pulleys and prevent proper functioning.

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Step 6: Replace Rear Pulley and Belt

i.

Turn rear pulley upside down.

ii.

Grip and hold down spring-loaded plate.

iii.

Hold spring-loaded plate with one hand.

iv.

While holding down spring-loaded plate, grab

belt with other hand and loop belt around the
exposed area, located above the spring-loaded
plate.

v.

Replace rear pulley and belt into CVT case.

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Step 7: Reassemble Front Pulley, if necessary*

*As previously mentioned, small hardware may fall
from front pulley upon removal. If the hardware fell
from the pulley, follow the guide below to
reassemble. If the pulley remained intact, skip ahead
to step 8.
Front Pulley Assembly:
Parts in diagram (to the left) are ordered from base
to top of front pulley.
(a) Base
(b) Pegs
Fit into the matching crevices of the base.
(c) U-shaped Washers
Fit into the u-shaped crevices located on the
edge of the plate.
(d) Plate
Fits (w/u-shaped washers) on top of base
level. Must be flipped from position pictured.
(e) Shaft
Fits into hole of plate and base.
(f) Pulley Face
Fits on top of shaft.
(g) Washer
Fits on top of pulley face.

Step 8: Replace Front Pulley into CVT Case

i.

Face front pulley with pulley face facing

toward you.

ii.

Loop left side of belt around front pulley.

iii.

Push pulley onto spoke located on the left

side of the CVT case.

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Step 9: Attach Front and Rear Pulley to CVT Case

NOTICE

Tap the impact gun trigger when

removing bolts. Holding the impact gun
trigger will cause damage to bolts and
other nearby components.

i.

Replace rear pulley bolt with impact gun and 14mm socket attachment.

ii.

Replace front pulley bolt with impact gun and 17mm socket attachment.

Test bolt replacement using fingers

to turn bolts. If the bolt does not move, the
bolt is set. If the bolt does move, repeat the
trigger tap method of bolt replacement.

Step 10: Test CVT

Test scooters CVT before replacing
the CVT cover, to prevent any need for
removing CVT cover again. If any
components were improperly replaced,
there is no need to re-open CVT cover.

i.

Turn on scooter.

ii.

Observe the front and rear pulleys.

iii.

Front pulley should contract, while rear pulley expands.

Step 11: Replace CVT Cover

i.

Check CVT cover to ensure the gasket is still

intact.

ii.

Replace CVT cover over CVT.

iii.

Tighten all bolts by hand, to reattach CVT

cover.

iv.

Tighten all bolts with 8mm socket wrench.

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Step 12: Replace Air Box and Kick Start Lever

i.

Reattach air box.

ii.

Screw air box screws with Phillips screwdriver.

iii.

Reattach kick start lever.

iv.

Tighten kick start bolt with 10mm box end wrench.