Author Topic: Belt Clutch and variator inspection after shudder  (Read 686 times)

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Belt Clutch and variator inspection after shudder
« on: April 09, 2017, 07:38:41 PM »
HI, I bought a 2010 SYM HD200 EVO at a tow auction with 10k miles.   I noticed a shudder when accelerating from a stop.  I opened up the CVT to find the clutch bell very blue on the outside and with a couple small scratches inside. The clutch pads seem to be missing a chunk on the edge. The belt is a bit frayed at the edge.  I accidentally broke the variator drive face as I removed the very tight variator nut.  One of the rollers appears to have a flat spot and the slide plates fit a little loose and look worn at the edge.

I'm a bit of a novice.  Based on the photos, can you confirm that I need:
belt
clutch and bell
rollers
slide plates
variator drive face
anything else?

Seems like oem parts are wildly expensive.  What aftermarket parts do you recommend.  How about this ebay performance clutch?  http://www.ebay.com/itm/performance-Clutch-kit-for-SYM-Joyride-RV-150-180-200-HD200-HD-200-/232162858410?hash=item360dfc15aa:g:Bs0AAOSw5cNYQo1T&vxp=mtr

What size Dr. Pulley Sliders should I get?  Thanks for helping out a newbie.








« Last Edit: April 09, 2017, 07:55:58 PM by Narzio »

Syd

  • Global Moderator
  • Sr. Member
  • *****
  • Posts: 329
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #1 on: April 11, 2017, 12:32:48 AM »
Looks like you have a broken fin on the outer variator half.  When you pulled the cover off did pieces fall out?

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #2 on: April 12, 2017, 03:44:03 AM »
I broke the fin and one of the two holes for the removal tool when I tried to remove the nut.  It was on so tight, the tool busted through the hole and a fin broke in the chaos.

Syd

  • Global Moderator
  • Sr. Member
  • *****
  • Posts: 329
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #3 on: April 12, 2017, 11:49:40 AM »
I broke the fin and one of the two holes for the removal tool when I tried to remove the nut.  It was on so tight, the tool busted through the hole and a fin broke in the chaos.
Yikes, I hadn't noticed that.

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #4 on: April 19, 2017, 11:24:29 PM »
I wound up buying a prodigy clutch http://www.ebay.com/itm/232162858410

and a prodigy variator http://www.ebay.com/itm/332167033749

$230 shipped for both.  Can anyone tell from the photos if I need a new belt?

Tromper

  • Sr. Member
  • ****
  • Posts: 334
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #5 on: April 20, 2017, 02:04:43 AM »
You'd have to measure the belt for sure, my old one was good after ~6k miles & I still have it kicking around, but I replaced it since I was in there anyway.
Belt spec from the manual is 18.5mm or above. at the top (wide part) \ /
Harbor Freight sells a cheap plastic caliper which is good nuff for this if you don't have one already.
08 SYM HD200
07 Suzuki Burgman 650

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #6 on: April 20, 2017, 11:43:41 PM »
Prodigy clutch and variator arrived!  Clutch bell is drilled and lighter.  Clutch shoes are longer, more contact area.  Variator drive face fins are ground down to be lighter.  I got rollers in 12g, 13g, 14g, and 15g.  Which weight do you recommend?  I think stock is 16g.






Tromper

  • Sr. Member
  • ****
  • Posts: 334
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #7 on: April 21, 2017, 05:03:42 AM »
Very shiny.  Stock shows as 14.5 in the manual.  I've always been happy with stock in the HD. 
Maybe try the 14s and long as they don't kill your functional top end or mpg too bad stick with those.
08 SYM HD200
07 Suzuki Burgman 650

deedee

  • Jr. Member
  • **
  • Posts: 66
  • Denver, C0 www.meetup.com Denver Scooter Group
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #8 on: April 21, 2017, 05:44:08 PM »
I love Prodigy parts.  Very well made, much cheaper than Malossi of Polini.  Never had much luck with their rollers.  Seem to wear out much quicker than stock.  Be sure to keep an eye on them.   I have Dr. Pulley sliders in everything I own.  Have a set in my Yamaha with 14,000 miles on them.  Still weigh exactly the same as when I installed them, and show virtually no wear. 

scosgt

  • Hero Member
  • *****
  • Posts: 1303
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #9 on: May 01, 2017, 12:41:40 AM »
sttock is 16g not 14.
the blue in the clutch bell is normal. they come that way new

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #10 on: May 09, 2017, 05:40:51 AM »
I installed 14g rollers. I also have 15g spares.  Should I swap them out?

Tromper

  • Sr. Member
  • ****
  • Posts: 334
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #11 on: May 09, 2017, 05:00:04 PM »
Ride it.  If you like it then just go with it.  If you're a bit meh try the heavier ones.
I did a bit of poking 'round and despite the manual U.S. stock weight is 16 by the look of things.
Makes sense since I've never seen a 14.5 for sale anywhere.

With the 14s you'll have a little better acceleration at the expense of higher revs and a bit lower MPG.
Top end will probably not be impacted, it usually takes a big change to do that since the variator will still open all the way at some point.

Living in a hilly region I was debating bumping mine down a gram or two.  Last time I just bought OEM from the dealer without looking so I'm probably running 16's.
08 SYM HD200
07 Suzuki Burgman 650

Narzio

  • Newbie
  • *
  • Posts: 7
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #12 on: June 12, 2017, 02:14:59 PM »
Got it all together, and changed spark plug, gear oil, and motor oil.  It hauls ass.

Tromper

  • Sr. Member
  • ****
  • Posts: 334
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #13 on: June 12, 2017, 06:05:43 PM »
Good to hear Narzio,
What weights did you wind up using?
How's the MPG holding up?
08 SYM HD200
07 Suzuki Burgman 650

Homer Sympson

  • Jr. Member
  • **
  • Posts: 83
    • View Profile
Re: Belt Clutch and variator inspection after shudder
« Reply #14 on: June 20, 2017, 07:03:10 PM »
Please tell me you put a new belt in!