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'06 Buddy 125

OK, I removed the transmission cover, installed the new Dr. Pulley sliders, put it all back together and started it up on the center stand. Now there is a loud metal clanging. I removed the cover again, made sure everything looked lined up properly together and tried again. Seems a little less loud but it's still there and gets very loud if I give it a little throttle.

What have I done? Did I trash it, if not what do I do to fix it?

I am sure Ben will see this, Kevin. I had to remove mine after the Lexington rally because I was having trouble with them "sticking" and I was always in 2nd gear. Kurt has been very successful with his but I don't know what went wrong with them in my bike. I was so bummed about it because they seemed to do a good job initially.

I'll make sure I ask Ben if he has a clue.

Well, real quick off the top of my head I can think of 5 possibilities...

1- The rollers are installed incorrectly, they're rotation sensitive. Make sure the words "Dr Pulley" are readable from the side when you remove the ramp plate.


2- The variator is not tightened all the way on to the shaft. (I've done this) The outer variator plate slides over the splines on the shaft, then the crown looking washer goes over the splines as well, then the flat washer and the nut.
Part number 33 and 26 must both be fully on the splines of the output shaft. (crank)


3- One or more of the little U shaped slidey deals is broken or missing. (item #30 in the above diagram)

4- The movable face and sliding boss are sticking together. (item #25) These 2 thing have to slide very smoothly. If you hold them in your hand horizontally the boss should almost be able to fall through the movable face. The boss should be shiny chrome clean and the inside of the movable face should be a brown/bronze color. Clean these with a rag and a lot of elbow grease. No solvents and NONONO sandpaper. (I use a cotton polishing wheel and jewelers rouge on the boss)

5- The moveable face is just worn out and the sliders can not slide in the ramps.

Let me know what you find.

I've taken the whole thing apart, and I'll have another go at putting it all together, hopefully right this time, after work.

Good luck!

Thanks for all the info Ben, I do appreciate it!

Any advice on getting the belt back on?

When I put it back together before I had loads of trouble getting the belt on, then it just suddenly went easy, I don't know why. So... now I can't seem to get the belt back on again....

I fear I'll get it all back together and still have the same noise problem, but I remain hopeful that I can get it all back together and ride knowing I'd done it myself and hopefully learned a thing or two in the process.

lobsterman wrote:
Any advice on getting the belt back on?

OK, what has probably happened is the clutch pulley has closed due to the lack of tension on the belt. (it's spring loaded.)
Easy to fix, hard to explain...

The clutch pulley, because of the spring, wants to be in the closed, large diameter position. If you compress the spring the pulley will spread open and allow enough slack in the belt to make it easy to slip over the variator shaft.

If you put the palms of both hands on the clutch bell (item #21) and your fingers on the face of item #16 (where the belt rides) and squeeze, you will compress the spring / open the pulley. The trick is in that the pulley face doesn't come straight back, it rotates clockwise. So you have to hold the clutch bell so it doesn't rotate with your palms, while you rotate your fingers clockwise with the pulley face.
Once you have the pulley open, hold it open with one hand and use the other hand to stuff the belt down into the pulley. Hopefully at this point the belt will hold the pulley open and you can slip the belt onto the variator shaft, install the outer variator face, crown nut, washer and nut.

Keep us updated...

OK, it's all back together and not making any noise, it sounds beautiful.

I have ridden it up the driveway and back a couple of times and it's acted the way it's supposed to so far, and sounds right. I'll be going out for a little shakedown ride in the neighorhood after I have some dinner.

Thank you so much lagerhead for all the excellent information and advice. It has made all the difference.

I'll leave it at that until after I ride it on the road to confirm success.

Rode a couple of miles in the neighborhood, no speed limits over 35 here so I can't say completely, but I think it's good. Sounds like maybe it's revving higher than before around 40 mph and the throttle response seems a little different, but I am not positive about that until I ride it some more in various conditions.

Awesome!
I'm glad to help.
Dr Pulley sliders do behave differently than rollers in the way they move up the ramps as RPM's increase. It seems like they tend to keep the engine spinning faster at a given road speed than rollers. A lot of people go 1 or 2 grams heavier when they switch.

There are 2 proven recipes for overcoming most mechanical situations-

#1- Patience, diligence and resourcefulness

--or--

#2 - Humility and a credit card.

Congratulations.