DOS Cycles Derbi/Honda variator - More range for 16x13 weights

The DOS variator is designed for 18x14 roller weights. It's pretty difficult to find any 18x14's in weights light enough to work on my moped so i'm going to use 16x13's. The variator is pretty nice, cheaper and cleaner casting than a TJT although a tiny bit heavier. A brand new Endurance belt runs perfectly to the top of the ramp with the variator maxed out.

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So with the variator open, the lowest the belt will go is 10 or 12 mm from the bottom because it's designed to hold 18x14 weights..

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So the inside area around the bushing is what you need to cut down. I used a dremel cut off wheel, first just leveling it to the tops of the roller fences and them smoothed it out. I removed 1.5 mm. If you had a mill or a lathe this would be easier, but a dremel works fine.

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Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

So now there is a gap between the ramp plate and the bushing because the ends of the ramps are touching, cut 1mm off the sharp edge of the ramp plate (left is cut, right is sharp)..

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and cut the very top of the casting in the variator (marked in blue)

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So it looks like this..

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Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Question is, does the pulley fully close with the smaller weights when actually spinning?

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Now the belt rides almost all the way down with 16x13 weights. This is a new belt so i imagine with a little wear it will be right to the bottom. The 16x13 weights can easily close the variator to bring the belt all the way to the top.

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Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Totally normal JBOT /

You can turn down the clutch bell pulley at least 2mm to get the belt all the way down.

Did my hobbit and it ruled.

Then if the spacing is too great just add a garbage plastic washer between the vari back hub and the ramp plate with the washer floating on the center, just using it to cinch up the belt

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Totally normal JBOT /

Oh, I forgot to add,

If it's like the tjt, you can get more spacing still by cutting the hub a touch more, then cut each ramp on the ramp plate back about 1/8in.

doesn't affect anything but it allows more belt spacing.

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Gotta get me a mill or a lathe...

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Charles Cole (OFMC) /
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Not that hard to make weights any size or weight. Mix & match brass & aluminum tubing to get desired weight. (edited)

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Totally normal JBOT /

That's clever

Re: DOS Cycles Derbi/Honda variator - More range for 16x13 weights

Very. Great idea.

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