MOPED ARMY

Thanks Bret.

Yeah, this project pretty much drained me as it is. I really don't want to buy anymore speed stuff right now.

I filed down the offending part of the giant 32mm hex nut. Now just the center part of the vario will rub... if it does. I don't have good snap ring pliers... and its a real pain to test fit things when it takes 1 hour to get the inner ring off. BUT, I had this idea to put one of the super-thin vario spacers between the inner cheek and case, for safety sake. Once I set the inner snap ring, I can play with the outer spacing to keep it away from the case but I'm afraid to snap the inner on yet because its like, do and/or die. There is just no way to know if it will rub the case without a test fit. So frustrating. So I'm sitting here drinking a beer and contemplating my next move.

Yea I am with Brett.

oh, i forgot that I was using the stock AV10 cases. you may have a different problem than me, but the only difference that I am aware of between the two variators is that fixed cheek edge.

The spacing issue you are having might be related to the thin washers that go between the circlips. did you mix up the thick and thin washers? That spacing is really touchy.

The cheeks might have hit the case bolts, but I cut them down pretty short before assembling. When I came to my senses, and got a tip from Moby Rebel, I put the vario on and put the inner clip on. Once the spacing for the outer clip is on, it keeps it away from the case (if you set it to .1mm play that is). So all is good with clearance. BUT, now, I noticed my belt is not even close to being aligned. I wonder if AV10 motors are slightly offset from AV7?

I'm not sure what to do. I might trim down the long cylindrical spacer on the right side, and then add a washer or two on the left side to compensate. Anybody else have this problem?

I grinded down the little spacer that pops in the head to shimmy it a little more to put me closer to alignment at variation. Try to get the inner cheek of the variator to align with the inner rim of the pulley as much as possible.