DIY - CVT Assembly Installation

Updated the  CVT Repairs  document with the CVT Assembly information.

Also uploaded the corresponding videos:

Step 1-1
Step 2-2
Step 3-3
Step 4-4
Step 5-7

Video - CVT Case / Cover Assembly

Uploaded the videos for the remaining steps for the CVT Case / Cover Assembly.

Steps 13-14
Steps 21-24
Steps 25-25
Steps 26-26
Steps 27-27

DIY - CVT Case - Cover Assembly update

Updated the  CVT Repairs  document for steps 13-14, 21-24, 25-25, 26-26 and 27-27, which completes the CVT Case / Cover Assembly procedure.

Video - CVT Case / Cover Assembly

Uploaded the videos for Steps 11-12, 15 and 16-18 of the CVT Case/Cover Assembly.

Step 11-12
Step 15-15
Step 16-18

DIY - CVT Case / Cover Assembly - Steps 19-20

Updated the  CVT Repairs  document for steps 19-20 of the CVT Case/Cover Assembly.

Also uploaded the accompanying video for the steps.

Steps 19-20 - CVT Case / Cover Assembly

Video - CVT Case / Cover Assembly Steps 1-10

Uploaded the videos for steps 2-10 of the CVT Case / Cover Assembly.

Step 2
Step 3
Step 4
Step 5
Step 6
Step 7
Step 8
Step 9
Step 10

DIY - CVT Case / Cover Assembly

Update Steps 1-10 of the CVT Case / Cover Assembly with complete instructions and pictures.

  CVT Repairs 

Video - Secondary Pulley / Idle Gears Installation

Uploaded the videos for the secondary pulley and idle gears (1) and (2) installations.

Step 1-2
Step 3-3
Step 4-4
Step 5-5
Step 6-6
Step 7-7
Step 8-8

Videos - CVT Belt Installation

Uploaded the videos for the CVT Belt Installation:

Step 2-3
Step 4-4
Step 5-5
Step 6-6

DIY - CVT Belt Installation

Updated the  CVT Repairs with new material and pictures for the CVT Belt Installation.

Videos - Primary Pulley Installation Steps 3-9

Uploaded the videos for steps 3-9 of the Primary Pulley Installaiton:

Step 3  Step 4  Step 5  Step 6  Step 7  Step 8  Step 9

DIY - CVT Primary Pulley Installation steps 3-9

Updated the  CVT Repairs  doc with the Primary Pulley installation and pictures
for steps 3-9.

Videos - CVT Case - Cover Parts Assembly

Uploaded the videos for the following:

CVT Case-Cover Parts Assembly Step 2-2 (Primary Pulley Bearing Retainer)
CVT Case-Cover Parts Assembly Step 3-3 (Primary Pulley Oil Seal)
CVT Case-Cover Parts Assembly Step 4-4 (Secondary Pulley Oil Seal)

DIY - CVT Case - Cover Parts Assembly

Updated the  CVT Repairs  with new data and pics for the primary pulley bearing retainer, oil seal and secondary pulley oil seal

Video - CVT Primary Pulley Bearing Installation

Uploaded the video for the Primary Pulley Bearing Installation

CVT - Primary Pulley Bearing Installation

DIY - CVT Primary Pulley Bearing Installation

Updated the  CVT Repairs document with new pictures and instruction for the Primary Pulley Bearing Installation. (Case / Cover Parts - Assembly Step 1-1)

Video - Uploaded the videos for CVT Case - Cover Disassebmly Steps 1-3

Uploaded the videos for steps 1-3 of the CVT Case - Cover Disassembly

Step 1 ---> Remove Primary Pulley Seal
Step 2 ---> Remove Bearing Retainer
Step 3 ---> Remove Primary Pulley Bearing

DIY - CVT Case - Cover Disassebmly Steps 1-4

Updated the  CVT Repairs   doc, CVT Case-Cover Steps 1-4.
Added new pics with completed steps by steps instructions.

DIY - Primary Pulley Assembly (New)

Updated the  CVT Repairs  with some new material:

- added the new parts list for the CVT assembly rebuild along with pics
- added the special supply list
- Updated the Primary Pulley Assembly section with new pictures of the old vs the new pulley assembly.

CVT Repair / Parts List

I placed my parts order for the CVT rebuild.  I went with my favorite local dealer in Van Nuys, CA who pretty much beat and matched the cheapest online deals I could find.

Below is my parts list for the rebuild:

10 -- 21747-10G00 O RING,PRI PULL -----$6.86
9 -- 21071-10G10 PULLEY ASSY,PRI ---- $641.61
12 -- 21751-10G00 BEARING,PRI PUL ---- $25.31
11 -- 09280-21014 O RING,D:1.2,ID ----- $1.57
11A -- 21757 - 10500 Seal, Primary Pulley - $10.90
17 -- 21756-10G00 BOLT,PRI FIXED ------ $3.74
28 -- 21916-10G00 O RING,CVT CASE --- $8.51
31 -- 27601-10G00 V BELT,DRIVE -------- $304.14
37 -- 21077-10G00 GEAR ASSY,ACTR ---- $44.23
25 -- 21852-10G10 Seal, Secondary ------ $12.23
39 -- 21078-10G00 GEAR ASSY,ACTR ---- $54.49
47 -- 08319-31103 Engine Mount Nut ---- $2.45

-------------- ----------------------------Total: $1,116.0

going to hold off on the shim kit until I have had a chance to install the new primary bearing and do 
the shim measurements

9A -- 21746-10G00 SHIM SET,PRIMAR $24.49

Video - Primary Pulley Removal

Uploaded two new videos, one documenting the removal steps for the Primary Pulley on a Burgman 650 and another showing the primary pulley in action.

Video - Primary Pulley Removal
Video - Primary Pulley in Action

DIY - CVT Repair - Primary Pulley Extraction

Update the CVT repair DIY with the latest pics for the Primary Pulley Removal steps.

 CVT Repairs 

Video - CVT Secondary Pulley Removal

Uploaded the video for the Secondary Pulley removal.

Video - Secondary Pulley Removal

DIY - CVT Repair

Updated the CVT Repair doc with the latest pictures for the Secondary Pulley removal procedure.

 CVT Repairs 

Video - CVT Case / Cover Separation

Uploaded the video for the CVT Case / Cover Separation

 CVT Case / Cover Separation

DIY - CVT Case / Cover separation

Updated the CVT Repair DIY with the latest pics for steps 10-11 which cover the CVT Case/Cover separation.

 CVT Repairs 

DIY - CVT Special Tools

Update the   CVT Special Tools  with the latest addition of the home made equivalent tools 

Video - CVT Case/Cover Removal steps 1-9

Uploaded the videos for steps 1-9 of the CVT - Case/Cover Removal :

Remove PPS
Remove Secondary Pulley Revolution Sensor
Remove CVT Motor
Remove CVT Filter Cover
Remove CVT Filter
Remove Secondary Pulley Shaft Nut
Remove Secondary Pulley Adapter
Remove Primary Pulley Bolt
Remove Primary Pulley Adapter

DIY - CVT Case - Cover Removal Steps 1-9

Updated the  CVT Repairs  DIY with pics and accompanying videos for the CVT Case/Cover Removal steps 1-9. 

CVT Assembly Removal Videos

Update the Phase 3 of the CVT repair DIY with pics, and added the video links for steps 1-5.

 CVT Repairs 


 Remove Bracket
 Remove CVT Bolts
 Install CVT Guides
 Remove CVT Bolts
 Remove CVT Assembly

DIY - CVT Assembly Removal

Updated Phase 3 of the  CVT repair project DIY.

 CVT Repairs 

DIY - CVT Special Tools

Started a new DIY for the home made version of the required CVT special tools which you can check here;

  CVT Special Tools