Orlando Scooter Maintenance Tips
Orlando Scooter Information
Orlando Scooter Information
Orlando Scooter Parts Service Repair Information Center
Orlando Scooter Parts Tech Center
Topic's Below:
Carburetor View, Transmission Oil Change, Roller Weight Installation, Clutch Spring Installation and Carburetor Jetting
Carburetor View / Description
Carburetor View, Transmission Oil Change, Roller Weight Installation, Clutch Spring Installation and Carburetor Jetting
Carburetor View / Description
Transmission Oil Change
Roller Weight Installation
1. Remove the kick starter from the CVT side cover.
2. Remove all the bolts with an 8mm socket that hold the CVT cover.
3. Remove the CVT cover, trying not to break the gasket; if you damage the gasket, I suggest you order a new one.
4. You have now exposed the front pulley (Variator) as well as the rear pulley (Clutch) with the belt connecting the two.
5. I always recommend installing a new belt, once you have the cover off, and are going to perform the upgrades.
6. Using an impact wrench (preferably), remove the nut holding the variator. Once you have removed the nut, remove the variator fan (outside part of the variator).
7. You can now slide the belt off the shaft (crank) and remove it from the clutch pulley as well.
8. Remove the variator by sliding it off the shaft, be carefull, as you need to reach behind the variator and hold on to the pressure plate as well, in order to prevent the rollers from dropping out.
9. Install the new roller weights into the new variator, making sure they are properly seated in their slots.
10. Slide the new backing plate onto the variator, making sure that the plastic sliders are also properly installed on the backing plate.
11. Holding the new variator securely with the backing plate, and the new rollers installed, slide it back on to the shaft. (do not install the new variator fan at this time)
Let’s move on to the clutch now:
1. Using the impact wrench remove the nut, holding the clutch & pulley.
2. Slide the clutch bell off the shaft.
3. This will expose the clutch & pulley assembly.
4. Slide the assembly off the shaft.
5. We are now going to install the new clutch and the new main (torque) spring.
6. If you do not have a professional clutch stand, follow my instructions, but be aware the main spring is under load, so be careful.
7. Place the clutch on a solid floor, with the clutch side facing up.
8. If you do not have help, place both you feet on either side of the clutch, placing pressure downward on the clutch, holding it in position.
9. Use your impact driver to remove the large nut holding the clutch, do this very slowly, as you remove the nut, then slowly release the pressure with your feet, and the spring will unload slowly, and clutch will come away, releasing the large spring.
10. Install the new spring & clutch, and reverse the process, compressing the spring with the clutch. (it is much easier if you have somebody help you with this part)
11. As you compress the clutch, be very careful not to cross thread the large nut, make the first few rounds by hand, and only then use the impact wrench to tighten the nut back on.
12. Slide the assembly back on to the shaft, install the clutch bell back on the shaft, be sure to line up the splines, and then tighten the nut back on the shaft.
Now we install the belt:
1. Place the belt over the clutch pulley.
2. Take both your hands (you will need somebody to help you here) and pull back on the clutch to open it slightly, let your assistant now push the belt slightly into the clutch pulley as you open it up. This allows the belt to reach over the front shaft. You only have to insert the belt a small way in.
3. Now pull the belt over the front shaft.
4. Now install the variator fan, be sure to line up the splines on the fan with the shaft, hand tighten the nut as far as it will go. Gently using the impact wrench, tighten the nut.
5. Install the CVT cover, with the new gasket, tighten all the bolts, on some scooters there may be a ground wire that you must not forget to bolt up as well.
6. Install the kick start lever.
Clutch Spring Installation
The tools you will need, long nose pliers, and a small flat screw driver:
1. Place the clutch down on a smooth solid surface, with the "C" clips facing upwards as in Fig 1.
2. Remove the "C" clips and remove the face plate see Fig 2.
3. Remove the clutch backing plate, be careful not to loose the small rubber stops, they will not be visible until you remove the backing plate, see Fig 3.
4. Remove the old springs, and install the new ones, see Fig 4.|
5. Replace the face plate, and re install the "C" clips see Fig 5.
Carburetor Jetting Installation
1. Once you have removed the storage compartment under the seat, and you can clearly see the carburetor, we can move to the next step.
2. Loosen the two clamps, one at the air intake side of the carb, and the other at the intake manifold.
3. Now, follow the electric wire from the choke, and unplug it from the harness.
4. Remove the fuel line at the carburetor, as well as the vacuum hose from the intake manifold.
5. The last thing to loosen is the throttle cable. The carburetor should now be ready to remove from the scooter.
6. Gently twist the carb and remove it from the two rubber boots.
7. Pour out and dispose of any gasoline left in the carb.
8. Work on a clean flat surface.
9. Turn the carb upside down, so that the bowl faces upwards (Fig 1.).
10. The bowl is held on by 4 screws.
11. Loosen and remove the 4 screws.
12. The bowl should now come away from the carburetor.
13. The jet will be very visible, it is brass with a slot in it (Fig 2.).
14. Gently using a flat screwdriver remove the jet, be careful not to unscrew the entire brass tube, only the small jet at the top of the brass tube (Fig 3.)
15. Now install the new jet, and gently tighten it, do not over tighten.
16. Reverse the process, re installing the bowl.
17. Place the carburetor back in the scooter, reconnecting the fuel line, vacuum hose, and throttle cable.
18. Don't forget to tighten the two clamps.