103 variator seal worked its way out?

David Ciao /

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Sep 09, 2009 04:56PM

so i was replacing a bad seal from the outside so i didnt have to crack my case. did so yesterday, took the variator off, screwed 2 wood screws into the old seal a little and tugged it out(thanks lee)

took my brand new seal, pushed it in all nice and even turned my bike on and to my joy no more air leak and faaast.

rode around about 20 minutes trying it on hills and flats, heating it up. come home cause some neighborhood nogoodnicks are walking around my basement door and i figure i should do a hot check for air leaks. look down at the seal and it is about 1/2 way out, against that little washer with the weird hole for the crank.

????? dirt or oil on case when I installed?

weirdness?

There is a little gouge near the seal on the crank, could that be grabbing just the edge of the seal and then working it all out!?

i have another brand new seal, take it out, clean it up try again?

Re: 103 variator seal worked its way out?

billyburgles /

billyburgles

Sep 09, 2009 07:23PM

shis it poshible to shim it shup so it shwont shimmy out?

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 09, 2009 08:19PM

i dont have the stock metal cover foam piece which has been suggested to be the reason for this. I do have the stock cover, but not sure about the foam ring. Any one have any ideas how to fashion one/ out of what?

Re: 103 variator seal worked its way out?

naz /

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michaeln

Sep 09, 2009 10:06PM

the foam piece for stock goes on the magneto side. The only thing that I've ever seen holding that seal in is the little metal cover the screws in over the seal.

Re: 103 variator seal worked its way out?

Gene Gindling /

gene_gindling

Sep 09, 2009 10:11PM

Try loctite red. Machinists also use lots of super glue gel.

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 12:05AM

hmm, that is one of the solutions i like best so far

Re: 103 variator seal worked its way out?

bigblockfiero /

bigblockfiero

Sep 10, 2009 12:53AM

After the seal is in then take a punch and punch dots in the aluminum around the circumfrance of the seal. This will contract the hole diameter as tight as you want depending how many punch dots you make. All endurance racing engine seals are put in this way.

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 01:10AM

how does that work?

Re: 103 variator seal worked its way out?

Gene Gindling /

gene_gindling

Sep 10, 2009 01:34AM

When installing a new seal, always put a thin layer of grease on the lip. Keeps them from getting wiped out before oil reaches them.

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 03:58AM

lip being which surface, inner/bearing around crank? around case?

i'm thinking bearing...

Re: 103 variator seal worked its way out?

Tommy Too Tall /

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thomasw

Sep 10, 2009 12:26PM

The lip is the part that touches the crank, dry=bad.

Re: 103 variator seal worked its way out?

peter /

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peter

Sep 10, 2009 01:20PM

i punch "tabs" into the cases in situations like this like how "bigblockfiero" mentioned.

Also when rebuilding motors to begin with, moreso on the engines with larger seals (puch, minarelli), i make punchmarks into the machined seal areas so when the engine gets put together the rubber from the seals "bite" into the punches and stay put better. never had one walk out when i punch them.

Re: 103 variator seal worked its way out?

naz /

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michaeln

Sep 10, 2009 01:21PM

I'm not sure how it could even work it's way out still with the metal cover that goes over the side. Mine contacts the seal so it gets held in directly with that piece. Does the metal cover you have sit a little bit away from the seal? Can't you just tap that metal piece down to put it contact with the seal? I suggest like other have putting a oil on the inner lip of the seal.

http://silverninja.net/~naz/mopeds/2009-09-10%2009.02.31.jpg

This metal plate.

http://silverninja.net/~naz/mopeds/2009-09-10%2009.02.44.jpg

Little more detail.

Re: 103 variator seal worked its way out?

naz /

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michaeln

Sep 10, 2009 01:22PM

oops meant to not make those links..

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 04:04PM

yeah, when i put the polini cases on my 103 i didnt have screws for that plate, seems like it may be the main issue

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 06:51PM

any idea on the sizing on those? anyone?

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 06:52PM

size of the case screws for the cover..

Re: 103 variator seal worked its way out?

Trina R /

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trina

Sep 10, 2009 07:33PM

Um the stock ones are kinda strange, think they are kinda like sheet metal screws. Can't remember what the polini takes but seems like it's something odd. I vaguely remember having trouble locating the right screw.

-naz

Re: 103 variator seal worked its way out?

David Ciao /

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davidw OP

Sep 10, 2009 10:18PM

i picked up 20 random sets, 2 worked perfect. that cover does hold that seal almost RIGHT in there. i am going to start right there, with just the cover and now ride ride ride and see

god. i think this has been a problem for most of the life of this bike. finally solved?

thanks!

MOPED ARMY

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