The Honda PCX / Forza / ADV150 / SH Forums

I know nothing about opening up my bike and installing variators and such. Is there anything that would improve performance that's more of a screw on or plug in? Also, I'm about 215lbs on my PCX150, I'm assuming weight has something to do with speed? Thanks.

Installing a variator requires 15-20 minutes maybe 30 the first time. It takes three different sockets and an impact. There are eight or ten 8mm bolts to take the variator cover off. Then you need a 22mm 6 point impact socket and an impact gun to remove your variator. With your hand flat against the outter pulley half and your fingers outside the housing so only your palm is putting pressure on the pulley give a few short bursts on the impact to break the nut loose and spin it off. If your replacing the belt with a reinforced belt, you'll need an 18mm or 19mm socket to remove the outter clutch bell. This is similar to removing a brake drum on a car. Then you slide the rear pulley assembled off the rear shaft. This enables you to replace the belt easily. When you go to put the variator on you will need to place a copper crush washer from your local hardware store on the engine case side to help prevent any vibration from the belt being too loose upon takeoff. Then force your rear pulley appart to let the belt go further into the pulley (there is a spring that keeps the pulley halves on the rear pulley pushed together.) them turn the variator by hand to keep the belt free as you tighten the nuts down with an impact again. Just tighten them until the nut stops clearly moving then a single half second pull on the trigger to torque the nuts.

If you choose to use your stock belt you'll most likely experience belt stretch within 1500 miles. A reinforced belt will give you another 8500 miles.

An aftermarket variator will enable faster acceleration and a higher top speed on the flats. Uphill you will have an improvement but don't expect to do over 55-60mph up hill on the highway. You'll need to do other things to make that happen like a new exhaust and intake.

Maddiedog has a great write up on how to do this. It's almost as easy as changing a tire. It's really the simplest and cheapest mod for your scooter.

The most expensive variators will enable you to go over 75 mph on a flat while others will add lots of acceleration but leave your top speed the same.

I suggest a takegawa variator from webike for $56 plus shipping. Probably around $85 to your door. A Yuminashi will cost around $170 shipped but will enable you to hit 77mph on a flat and 79mph down hill actuall speed. This is not a 10% over speedometer reading. The US spec pcx 150 speedometers are dead on.

Mgalutia88 wrote:Installing a variator requires 15-20 minutes maybe 30 the first time. It takes three different sockets and an impact. There are eight or ten 8mm bolts to take the variator cover off. Then you need a 22mm 6 point impact socket and an impact gun to remove your variator. With your hand flat against the outter pulley half and your fingers outside the housing so only your palm is putting pressure on the pulley give a few short bursts on the impact to break the nut loose and spin it off. If your replacing the belt with a reinforced belt, you'll need an 18mm or 19mm socket to remove the outter clutch bell. This is similar to removing a brake drum on a car. Then you slide the rear pulley assembled off the rear shaft. This enables you to replace the belt easily. When you go to put the variator on you will need to place a copper crush washer from your local hardware store on the engine case side to help prevent any vibration from the belt being too loose upon takeoff. Then force your rear pulley appart to let the belt go further into the pulley (there is a spring that keeps the pulley halves on the rear pulley pushed together.) them turn the variator by hand to keep the belt free as you tighten the nuts down with an impact again. Just tighten them until the nut stops clearly moving then a single half second pull on the trigger to torque the nuts.

If you choose to use your stock belt you'll most likely experience belt stretch within 1500 miles. A reinforced belt will give you another 8500 miles.

An aftermarket variator will enable faster acceleration and a higher top speed on the flats. Uphill you will have an improvement but don't expect to do over 55-60mph up hill on the highway. You'll need to do other things to make that happen like a new exhaust and intake.

Maddiedog has a great write up on how to do this. It's almost as easy as changing a tire. It's really the simplest and cheapest mod for your scooter.

Why do you need to dismantle the clutch and rear pulley to change the front pulley (variator)?

You don't but you might have to fit an "upgraded" belt

Mgalutia88 wrote:The most expensive variators will enable you to go over 75 mph on a flat while others will add lots of acceleration but leave your top speed the same.

Yes but the expensive ones come with everything you need. No shopping at a hardware store for a copper crush washer, no need to buy a "so-called' reinforced belt as they use a stock belt, no wondering if you have the correct weights, etc. just open the box follow the simple instructions. OK you need some basic tools or any competent scooter mechanic can do it for you.

If one is not mechanically motivated it is the simplest option.

Wasp mike, most variators can use the stock size belt. The issue is that the stock belt when used at its limit squishes thinner and stretches longer. It's not designed for "severe duty". The reinforced belts use Kevlar fibers to prevent squish and stretch.

Youyou, you don't need to remove the rear pulley however it makes it much easier for a first timer to do the install. You need to seperate the rear pulley halves to EASILY fit the belt over the drive boss. This is especially true of stiffer reinforced belts as we can't hold them at working tension with our hands. It's just a trick to make it easier.

I suggested this only as the OP doesn't want anything complicated.

What size is the stock belt?

Mgalutia88 wrote:
Youyou, you don't need to remove the rear pulley however it makes it much easier for a first timer to do the install. You need to seperate the rear pulley halves to EASILY fit the belt over the drive boss. This is especially true of stiffer reinforced belts as we can't hold them at working tension with our hands. It's just a trick to make it easier.

You dont need to undo the rear pulley to fit the belt easier. I just pull it with my hands open and slide the belt to the bottom of it,that gives me maximum looseness at the front pulley.

Pcxdemon wrote:

Mgalutia88 wrote:
Youyou, you don't need to remove the rear pulley however it makes it much easier for a first timer to do the install. You need to seperate the rear pulley halves to EASILY fit the belt over the drive boss. This is especially true of stiffer reinforced belts as we can't hold them at working tension with our hands. It's just a trick to make it easier.

You dont need to undo the rear pulley to fit the belt easier. I just pull it with my hands open and slide the belt to the bottom of it,that gives me maximum looseness at the front pulley.

I think we lost the OP at "It takes three different sockets and an impact"

Lol that could be very true...

Pcxdemon wrote:

Mgalutia88 wrote:
Youyou, you don't need to remove the rear pulley however it makes it much easier for a first timer to do the install. You need to seperate the rear pulley halves to EASILY fit the belt over the drive boss. This is especially true of stiffer reinforced belts as we can't hold them at working tension with our hands. It's just a trick to make it easier.

You dont need to undo the rear pulley to fit the belt easier. I just pull it with my hands open and slide the belt to the bottom of it,that gives me maximum looseness at the front pulley.

Ditto