Repair 7

Scooter clutches come in two general design categories: a clutch basket incorporates clutch cork plates; and a rotating wheel that uses shoes similar to a brake drum system to engage and disengage gears. Working on these clutches involves two sets of tools as well: specialty tools that need to be obtained from a manufacturer or dealer; and standard tools that can be purchased at any general hardware store.

Specialty Holding Tools

For clutch basket-type clutches on a scooter the clutch and crankshaft of the engine needs to be kept stationary. A clutch holding tool hooks into the side of the clutch basket and to the engine case. Doing so, when the clutch turns as it is loosened, it stops because of the hook, allowing the clutch holding nut to be loosened or tightened properly.

A different clutch holding type inserts into the clutch body and a mechanic keeps it still by hand while using a different tool in another hand to loosen or tighten the clutch.

Specialty Clutch Loosen/Tightening Tools

Clutch nut tools are specifically designed for certain scooter clutches that use a castellated nut. Similar to the wall top of a castle, a castellated nut has edges that go up and down. The clutch nut tool fits into these grooves to tighten or loosen the securing nut holding the clutch to the crankshaft.

Clutch pullers work the same way as a gear puller. The center of the tool positions on the end of the crankshaft. The clutch puller arms then positions behind the loose clutch and pulls the unit off the crankshaft arm without damaging it or the engine case.

Standard Tools

Socket wrenches and sockets see the most frequent use in tightening or loosening a clutch in a scooter engine. Because of the angle of the securing nut, a regular wrench cannot be used. The socket, instead, sits over the nut and is forced in direction or another by the socket wrench that attaches to the socket.

Screwdrivers sometimes provide a blunt but effective holding tool if they can be positioned correctly to stop the clutch from spinning when its being worked on. The risk, however, is that the hard metal of the screwdriver pressures against the soft metal of the aluminum scooter engine case, denting it.

Compression Tools

For basket clutches, a compression specialty tool is needed. This device acts the same way as the engine by pressing the clutch basket together, allowing the retaining ring that keeps the assembly together to be removed easily. Then the clutch plates and springs that are worn out can be replaced.

A small washer in your scooters variator system governs its top speed. Removal of this washer will allow your scooter to accelerate faster and operate at a greater top speed. In order to access this washer, you must remove the intake case and variator case lid. This will give you access to the variator system. Once inside the system, taking the governing washer off your scooter requires you to first remove the front pulley wheel in your variator to gain total access to the washer.

Instructions

1

Disconnect the kickstand of your scooter. The kickstand is attached to your scooter by a small metal pin that is tightened by a bolt. Crack the bolt and pull the pin partially out and you will be able to remove the kickstand.

2

Unscrew the two or three bolts holding the plastic molded covering to which the kickstand was attached. This covering is the intake cover. Removing it will reveal the variator system.

3

Unscrew the six bolts. Hold the metal, flattened, cylindrical lid onto the case, revealed when you removed the intake cover. This is the variator case. Removing the six bolts will allow you to remove the lid, giving you access to the pulley system and governing washer.

4

Detach the front pulley wheel from the variator system. Use an impact wrench to remove the bolt holding the wheel in place. An impact wrench is an air-powered socket wrench.

5

Extricate the small washer from the front pulley rod. This washer acts as the governor of your scooter, limiting the variator systems ability to perform at full capacity and dropping your scooters acceleration and top speed capabilities.

6

Put your scooter back together, starting with the front pulley wheel, the lid of the variator case, the intake case and finally by reattaching the kickstand.