How to remove the variator, clutch, belt, rollers on Honda - Kymco 125

First, unscrew the screws holding the variator cover. Once the fixed pulley half is visible, position the Easyboost variator locking wrench on it.

Using a ratchet fitted with a socket, loosen the nut to release the fixed pulley half, then the belt.

You can then easily remove the variator, the rollers and the ramp plate.

Loosen the nut holding the clutch bell using a ratchet fitted with a socket together with the Easyboost locking wrench.

The clutch bell comes out of its housing easily.

Draw a mark with a felt pen to note the position of the nut. Loosen the main nut holding the clutch on the torque driver using the clutch locking wrench and the Easyboost multifunction wrench. Warning: the purpose of this operation is only to loosen the nut by a maximum of 1/4 turn.

Once the nut is unlocked, set up the thrust spring removal tool following the instructions in the manual. This operation will release the clutch nut by applying slight pressure on the thrust spring. Warning: since the clutch is already at its stop, do not try to compress the spring any further.

Once the nut is unlocked, we set up the thrust spring removal tool following the instructions in the manual. This operation will release the clutch nut by applying slight pressure on the thrust spring. Warning: since the clutch is already at its stop, do not try to compress the spring any further.

All that remains is to unscrew the nut from the shaft to gradually release the spring safely.

The spring is removed; it can now be replaced with a new and/or stiffer model to increase torque and pick-up. For reassembly, repeat the operation in reverse order. Put the tool back in place so you can compress the thrust spring.

Once the spring is compressed, the clutch nut can be put back in place by hand.

For reassembly, repeat the operation in reverse order. Put the tool back in place so you can compress the thrust spring.

Repeat the same procedure as for disassembly, setting up the clutch locking tool. Using the open-end wrench, tighten the clutch nut until the marks drawn beforehand are aligned.

To make fitting the variator easier later on, first insert the belt slightly into the torque driver. To do this, simply compress the pulley flange on the clutch side.

Fit the torque driver on its shaft, fitted with the belt.

The variator nut must be retightened to a torque of 60 Nm using the Easyboost locking wrench and a torque wrench.

After refitting the clutch bell, tighten the nut to a torque of 50 Nm. All that remains is to screw back all the variator cover screws and refit the fairings.