cutting the case to fit bigger pulleys

ped · Post by **ped** » Sun Feb 01, 2015 1:00 pm

Hi forum. this may or may not be the right way to do it? But this is how I cut my case to fit bigger pulleys.
I use a dremel with the cutting bit, and sander tip. A grinder it's much faster, but you can damage your cases. It's too aggressive. Hope this helps someone.

ped · Post by **ped** » Sun Feb 01, 2015 1:02 pm

the front pulley is all set. You can see with the belt is going to rub. It needs to be trimmed down a bit or it will wear Down your belt.

ped · Post by **ped** » Sun Feb 01, 2015 1:05 pm

ped · Post by **ped** » Sun Feb 01, 2015 1:09 pm

ped · Post by **ped** » Sun Feb 01, 2015 1:12 pm

well the cases trim. Hopefully we can pro long the belt.

ped · Post by **ped** » Sun Feb 01, 2015 1:14 pm

ped · Post by **ped** » Sun Feb 01, 2015 1:15 pm

DirtyE · Post by **DirtyE** » Sun Feb 01, 2015 2:26 pm

Nice!

Xxbeejay45xx · Post by **Xxbeejay45xx** » Sun Feb 01, 2015 8:12 pm

Solid sir just what I needed to do mines Thanks a bunch!

DirtyE · Post by **DirtyE** » Sun Feb 01, 2015 8:44 pm

Can you show some pics of what to do with the front variator cover and the spacing so there is no binding.... at least that I've read about. Im not quite as far as you with my build so this is all great!

ped · Post by **ped** » Mon Feb 02, 2015 11:56 am

DirtyE wrote:Can you show some pics of what to do with the front variator cover and the spacing so there is no binding.... at least that I've read about. Im not quite as far as you with my build so this is all great!

Hi Dirty. I normally use gasket material glued to the front cover. But I've read that you can use very thin washers for spacing. There's a thread on it on here somewhere. When I get to that point I can post some photos.
there are other factors involved, maybe you need a little grease? Or the bushing is worn out? Take a look .

ped · Post by **ped** » Mon Feb 02, 2015 11:57 am

there is a little bushing for the kicker that wears out. There is a small washer behind the drive gear. And the drive gear.

ped · Post by **ped** » Mon Feb 09, 2015 5:33 pm

I also shaved the kick cover.

DirtyE · Post by **DirtyE** » Mon Feb 09, 2015 7:00 pm

I got around to fitting my pulleys last weekend. I cut just about everywhere you did, maybe a little less. I also painted inside my cases, so if the belt is rubbing somewhere I should be able to see it. Im running the 94mm polini vario and zx rear.

ped · Post by **ped** » Mon Feb 09, 2015 8:11 pm

Hi Dirty. I don't think it's necessary to shave as much as I did? As long you smooth it out a little.
I'm using polini vari, malossi belt, kymco rear ZX drive.

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cutting the case to fit bigger pulleys

cutting the case to fit bigger pulleys

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