Honda Spree and Elite 50 Forums

I installed a malossi variator. Now I can't get the kick start to work. I won't retract. I could look in with the clutch cover removed and see that there is not enough clearance now for the pawl to retract from the pulley. Do I have to take and shave the drive boss in a lathe to get the clearance I need? The drive boss with the variator is a bunch longer than the stock one. I had the cover off a gazillion times I cleaned and greased the starter assembly while I was at it .

run your stock boss not the one that come with it....
swimmingfree

Use washers to shim out your kicker from the cover. The malossi boss is a lot longer then the stock af18. You unfortunately can not use the stock boss with the malossi.

LoveMyHonda wrote:Use washers to shim out your kicker from the cover. The malossi boss is a lot longer then the stock af18. You unfortunately can not use the stock boss with the malossi.

Duh why didn't I think of that lol so I just need the space to kick her cover the same distance for the clearance ok makes sense. Thanks LMH. Maybe I'll go to the sheet metal place and have them cut me a spacer to fit hmmm.

You could have one made or use 5 m6 flat washers and put 1 on every hole. I put the top 2 in first then let it hang as you run the bolts thru the kicker and catch the washer behind it. If you can zoom in on mine you can see them.

LoveMyHonda wrote:You could have one made or use 5 m6 flat washers and put 1 on every hole. I put the top 2 in first then let it hang as you run the bolts thru the kicker and catch the washer behind it. If you can zoom in on mine you can see them.

Thanks so much. Washers are cheap custm cut metal is not lol I'll buy a pack of washers and let it rip. Added benifit of extra ventilation around the cover with washers

i had to do the same on my AF18 .You can run smaller bosses but why lose that extra belt movement it gives you way better take off .

sorry patthesoundguy for the bad info ...
swimmingfree

@greg, it's not bad info just, you just didn't know about the malossi. Malossi variators won't allow you to run any other boss but the malossi one. Polini won't allow any bosses besides the malossi or polini. You risk messing up the brass insert in the variator if you try to force another boss through or risk the variator seizing to the boss.

i try not to give bad info but we all f up now and then.... but its frytheday and im doing it .... lol....
swimmingfree

swimmingfree wrote:i try not to give bad info but we all f up now and then.... but its frytheday and im doing it .... lol....
swimmingfree

Lol frytheday.

swimmingfree wrote:i try not to give bad info but we all f up now and then.... but its frytheday and im doing it .... lol....
swimmingfree

I thought it was great advice nonetheless all good.

The washers totally did the trick now the malossi vari was ok. I have to play with it more
The winning combo right now is a koso Chinese vari with the rollers that cane in the motor and a red malossi spring out back. I have to weigh those rollers and see wwhat they are. I have mind blowing takeoff with wicked acceleration. Now my real issue is that the motor worked great for a quick test run then it refuses to rev up. It will go to about 35 mph when its cranky and will bury the needle in short order when its working properly. Its got lots of lubrication its 32:1. Temps well below 300f most of the time. New 8 plug. Seems that be fine when I first start it up. Then once I get it warm say 250f its soooo cranky above 1/4 throttle. Ive got a 125 jet in it so hard for me to think its possible its still rich. Others are running145 main with the same cylinder and 28mm ccarb. I have a couple spare coils and cdi boxes so I may try swapping them after iI try a new plug. Thoughts anyone?

if you get the zx drive face you should not have to shim the kick cover.

Well after not being home for 3 weeks I had a chance to try a new plug. That did the trick. Now I haveto jet back up t where it should be. I went for a short trip up the main road and wow how nice it was not to have to limp it home. I had to be careful on the temps diddnt take it past 300 and took it easy and cruised nice at 45 with not a lot of throttle.