Just received variator in the mail, have a few ???

[klone]

I just received a Kitaco variator in the mail and I am going to put it in tormorrow, or soon. There is a small tube of what looks like lubrication in with the variator as well, where does this go? Also, those that have taken the variator off, I have heard a strap wrench is needed, or at least helps, any idea on the size. I only have about 50 miles on the scotter, is it too soon to perform this mod. I am used to cars and know that waiting is important, but with this mod I did not think I had to.
Thanks

[lilruck]

I just used an impact wrench and it worked fine for the variator, but on my brand new Ruckus I couldn't get the rear bolt off that holds the clutch on. It was too tight.

[Dandy Dan]

Where did you buy the Kitaco variator? Anyways, the tube is lube....I got some with my Kitaco variator. Just put a thin coat everywhere except on the ramps were the belt rides and not on the roller weights either. You don't really need it but it's always nice to have things lubed.

It is never to soon to perform a variator mod. It just changes the gearing a bit. You might need a strap wrench but you can also just slide a bolt in between the fatter fins (notice that some are fatter than others to accomodate a tool) and let it hit the walls to stop the variator. A impact works good for taking the bolt off but it is bad for putting it back on because you can't accurately torque it. A strap wrench is universal tool so just get a pretty normal size and you'll been fine. The variator is maybe 6" in diameter.

[greendale]

dandydan said:

It is never to soon to perform a variator mod.

You'll be running at higher RPM on average if you change the weights and the new variator will let you go faster at top speed which equals more strain. If you're breaking in a new engine I guess neither is good, even if the difference may be neglectable.

[Dandy Dan]

greendale said:

dandydan said:

It is never to soon to perform a variator mod.

You'll be running at higher RPM on average if you change the weights and the new variator will let you go faster at top speed which equals more strain. If you're breaking in a new engine I guess neither is good, even if the difference may be neglectable.

You'd only be running at higher RPMs if you put lighter roller weights in too. A simple variator swap mainly just gears you taller at the top end so that you don't rev as high down hills and at cruising speeds. If you just swap the variator and keep the same or similar weights it would have less stress on your engine.

[greendale]

But at max speed on a flat road won't you still be at your max 8000 RPM most of the time if you only swap the variator? If you're going faster due to higher gears but at the same RPM as before that must mean that the engine is working harder, right?

I'm not just trying to prove you wrong, I'm trying to learn also. ;D

[klone]

I got the variator from VTcycles in Hawaii. I am going to use 6g roller weights as well, that seems to be suggested by others on the board. Is this a mistake? I also received a 1000rpm compression spring as well, but I don't think I want to get into the clutch just yet. Thanks for the info on the lube.

[Dandy Dan]

I got my variator from them too. First you should know that the compression spring won't work. I got two from them because they said that the springs from an Elite 50cc are compatable but they are not. The aftermarket spring you got is slightly too small in diameter and a bit too long. I emailed them yesterday about this. The 6g rollers weights should work good. Like greendale said they will increase stress slightly but it's really not a big deal. Everyone runs them.


Greendale: A stock ruckus will be at 8000rpm at about 41.5mph. When you cruise on a stocker you top speed is about 37mph which is roughly 7200rpm. With the aftermarket variator, the variator can close farther so with the same weights instead of reaching your max gear ratio at say 25mph you might hit it at 30mph (lighter roller weights would increase these speeds). Anyways, as a result at 37mph you will still be at the max gear ratio but the max gear ratio is different (I think 8k occurs at about 46mph) so you are putting along at roughly 6500rpm...much lower. However, because you are geared taller you can keep accelerating past 37mph to about 40mph. At 40mph you are still only revving at 7000rpm so you are revving lower than a stocker at 37mph thus less stress. You would actually have to reach about 41mph before you are revving at the same RPMs that a stocker revs at 37mph. This is the biggest advantage of the aftermarket variators.

Because the aftermarket variator has an increased 'stroke' (opens farther). It is geared taller on the top end without being geared taller on the low end. If you gear the stocker taller by shortening the spacer or something you gear it taller across the board and thus it gets sluggish off the line.

[chanito]

I understand your concern Greendale, installing an aftermarket variator is like changing the transmission on a car, changing the gearing always have an impact on an engine demands, but that is not always a bad thing, a new variator more than likely will make the engine spin faster before getting into top gear, but the torque curve of the engine makes this a good thing, once the engine gets close to 8k torque falls fast so the engine can not accel any more and normally will top at 7,8k, some times everything will be right and the engine will reach 8k, but i can't see that as the norm and more than likely it will be the exception to the rule, the engine in the ruckus is under-stressed, so it can take a lot of abuse, it can easily live at 9k all day long (but i feel a lot better at 8k, wear can be an issue at so high sustained engine speeds), now this breaking in period is not as important as it once was due to great new ring materials and cylinder finishing, however lubrication is a lot more important at high engine speeds, so keep the 600 miles oil changing intervals, and use a good quality oil

[greendale]

I'm once again making too many assumptions based on my own restricted Zoomer. Sorry.

I'm running close to max rpm all the time because of the different variator (lower max gear). I can be going uphill with a strong headwind and it's still easily humming along at max speed.

[chanito]

You are running close to max speed going uphill and against the wind? you have a very strong engine, consider your self very lucky, VERY LUCKY indeed

[greendale]

It's not a stronger engine. It's restricted by the variator to 28 mph, so it never reaches a tall gear. That's the only reason why it's strong.

[Dandy Dan]

Greendale, I forgot that you are riding a restricted euro Ruckus. That really simplifies the whole variator thing because stock you're cruisin at 8k almost all the time so you really can't get any higher stress unless you get a CDI.

I'm not sure how Honda can do that (not gear it taller) and not make cruising annoying. It seems to me that either you'd have to hit the rev limiter at 28 mph which would cause annoying backfiring and popping sounds or it could delay the ignition timing to drop your power off except then you'd get miserable fuel economy. Perhaps it somehow restricts the gas flow....

[klone]

I just completed the variator install, if I have done something wrong I am assuming I would know by now. It accelerates better and handles hills better. I have put about 12 miles on it since the install, should i know if something is wrong by then?

[chanito]

Great job Klone, congrats

[Dandy Dan]

The biggest thing is that you get the nut on tight. If it's loose things will rattle and wreck the variator and maybe the crankshaft. It's kinda hard to tell if it's tight or not because the belt is getting pinched in there so it feels tight before it is. Also I'd strongly suggest putting locktite on the threads where the nut goes. If that nut comes off when you're riding all of a sudden your revs will go through the roof and you'll hear a whirring sound. If this happens pull over and shut it off immediately.

It sounds like you did the job right though so good work. Any improvement in top speed? Did you replace the weights too?

[klone]

I am not sure if it helped out the top speed. Most of the roads I drive on are pretty hilly. I used to cruise at like 30 now I go about 35 and the hills don't kill my speed as much. Acceleration appears to be better as well.

[Kickass]

Greendale, Hi, I'm new here... Just a question, what variator do you use ? Or are you driving stock ? How much top speed do get ?

/ Confused Noobie

[cabuco2006]

i just got my variator kit from battlescooter and just put it in today...it runs so much better...i also could not get the clutch nut off...to tight....and a universal holder works great for this mod

[timberwolfmadcat]

Yeah, the aftermarket variators do 3 things
1) Better Acceleration - More room so you have a lower low gear, higher high gear. The aftermarkets allow you to use lighter wieghts without losing top end.
2) Better hill climbing - Due to the fact you can use lighter wieghts, your geared lower, making it easier to climb hills, allowing you to go faster up the hills.
3) More top Speed - Give you a higher gear on the top, allowing you to go faster on long straighaways, which makes it easier to hit top speed sooner with lighter wieghts