How to dismantle or change a variator, clutch, belt, rollers on TMAX?

Unscrew all the fixing screws of the air intake, footboard and rocker panel to allow free access to the CVT housing.

Once the fairings have been removed, access to the CVT housing is possible. The air filter must therefore be removed first and then the housing fixing screws must be completely unscrewed.

In order to remove the variator easily, the Easyboost variator holding tool, equipped with the 4 M8 screws and 4 M8 nuts, is required. This will enable the variator to be locked in place so that the nut can be loosened using a socket spanner or ratchet.

The variator nut can be loosened using a ratchet with a socket of 29 and the Easyboost spanner.

To remove the torque drive, place the 2 M6 screws and 2 nuts on the Easyboost multi-purpose spanner. This configuration enables the torque drive to be locked. Loosen the nut of the torque drive using a spanner fitted with a 27 " long " socket.

Tighten the 2 M6 screws at the locations provided on the torque drive so as to move the mobile flange away from the fixed flange. When the torque drive is completely off its axis, the belt will easily come out. Care must also be taken not to pinch your fingers when the belt comes out of its housing.

Place the Easyboost thrust spring removal tool on the torque drive/couple/spring assembly and tighten the nut. As the spring cup is already in the stop position, no attempt should be made to compress the spring.

The locking tool holds the thrust spring and now exerts a slight pressure on the cup. The nut of the torque drive can therefore be unscrewed by hand.

All that remains to be done is to loosen the axle nut so that the spring can be released gradually.

Once the spring is fully relaxed, it can now be safely removed and replaced with a harder spring to gain more torque and acceleration.

It is now a question of proceeding in the opposite direction of dismantling. Replace the new spring and the Easyboost thrust spring holding tool and compress the spring by screwing the axle nut until it stops.

Tighten the nut by hand and then remove the removal tool from the thrust spring. Using the two Easyboost spanners, tighten the nut of the torque drive until the 2 marks drawn previously are aligned.

The torque drive is now equipped with the new thrust spring. All that remains to be done is to put it back on its axis, having first inserted the belt between the two flanges.

Once the rollers have been replaced, the variator can be reassembled on its shaft.

The drive nut must be tightened to a torque of 160 Nm using the Easyboost spanner and a torque spanner with a 29 mm socket.

Using the Easyboost spanner and a torque spanner equipped with a 27 "long" socket, tighten the torque corrector nut to a torque of 90 Nm, as recommended by the manufacturer Yamaha.

The variation housing and the filter can now be refitted. Then all that remains is to reassemble the rocker panel, the footboard and the air intake to complete the operation.