Variator/roller replacement Issue

[camm59]

I am now on my third try to replace the rollers on my 2013 ruckus. At this point, I have a new belt, rollers, slide pieces, both drive faces, all oem parts. The problem I seem to be running in to and cannot figure how it came to be is when I install everything, there is about a 1/16” space or so between the variator nut/washer and the rest of the setup. What this leads to is rattling around, and the movable drive face (the three “tabs” on the back) wanting to grind on the crankcase. This is only an issue at idle, as that face moves away from the crankcase at higher speeds, but then the rollers get loose and destroyed very quickly, as my second go around taught me. The first failure I chalked up to installing dr. Pulley rollers the wrong way. Without the variator nut able to hold everything solidly in place, things are going to get destroyed, but I cannot figure where that space is coming from, and my only solution I have thought of so far is to place a washer between the ramp plate and crankcase to tighten things up. On the same topic and I can’t find this anywhere though I think I have it right, what way is the drive face boss supposed to go, as it has a slightly conical inner diameter? 

I guess put most simply, where is all the extra play coming from and how to address that?

pictures to help you understand the issue:

[Baizy]

Hey camm59 sorry to hear your rucks giving you grief!

Unfortunately the photos didn't come through, but I'll do my best here. Immediately I am concerned that your variator is able to scrape the crankcase. Is it possible that you have a poorly matched set of parts? When the rollers are correctly seated in the variator and the backing plate is put into place the variator face should be far enough out that it doesn't make contact, if it does one or more parts in that sandwich is incorrect. Once you determine if that is the problem you can place the variator assy, bushing, and drive face on the crankshaft. Then place the kickstart plate at the end of the shaft, this should have the whole spline covered. If not add washers to the stackup until it is just threads visible, only then should you wind the nut on the end of the shaft.

If you follow those loose instruction you should be good to go in no time flat!

[OddTodd]

So I was trying the whole variator swap, tried with sliders, but didn’t like the way it sounded afterwards, so ended up just putting the original back in, cause I figured I wasn’t doing something right. But anyways, I snapped the one 10mm bolt that holds that other piece to the crank case. Looked it up and could only find a Chinese gy6 bolt m6*40? So I ordered it, however when I bought one from autozone just to hold it till the one gets here, it’s too big, won’t screw in. Is this the right part? Or am I looking for something else? Sorry if this is in the wrong spot. I would put a picture but not sure how, so link?

azscooterparts.com/crankcase-bolt-m640-gy6-chinese/

[OddTodd]

Also, is it normal to hear a click right at the beginning of acceleration, im guessing as the rollers start to activate and make contact with the plates? I don’t hear it after that, while accelerating all the way up or decelerating, just right at the beginning before the belt starts to spread out.. This is just how I’m explaining it to myself as to convince myself jt’s okay, and is probly completely Wrong. If anyone knows what’s going on or has any pointers would really appreciate it. Thanks.