Thursday, November 1, 2012

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

Wednesday, October 24, 2012

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.

Saturday, October 20, 2012

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

Tuesday, October 16, 2012

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

Tuesday, October 2, 2012

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 

Friday, September 28, 2012

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.

Wednesday, September 26, 2012

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.

Thursday, September 20, 2012

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

Thursday, September 13, 2012

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)

Sunday, September 9, 2012

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.

Monday, September 3, 2012

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.

Tuesday, August 21, 2012

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

Thursday, August 9, 2012

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

Wednesday, August 8, 2012

DIY - CVT Repair - Primary Pulley Extraction

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

 CVT Repairs 

Friday, August 3, 2012

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 

Tuesday, July 31, 2012

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 

Wednesday, July 25, 2012

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

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. 

Tuesday, July 17, 2012

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 

Sunday, July 8, 2012

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