Installation &

Maintenance Guide
VSP 2000 / LP2 (version 2)
Variable Speed Power
Transmission








CVTech-IBC inc.
300, Labont St.,
Drummondville (Quebec)
Canada, J2C 6X9

CVTech-IBC Europe
9, rue de Montevi,
49280 LA TESSOUALLE
France
Document : 0046-5127
www.cvtech-ibc.com December 2007
Table of Contents


Important Notice....................................................................................................3
Maintenance Frequency........................................................................................3
The Necessary Handling Tools.............................................................................4
Transmission System Parts....................................................................................5
Installing the Pulleys onto the Vehicle..................................................................6
Installing the Driven Pulley................................................................................6
Installing the Drive Pulley and Belt...................................................................6
Bolt Tightening...................................................................................................7
Removing the Pulleys from the Vehicle...............................................................8
Drive Belt Inspection........................................................................................10
Disassembling and Reassembling the Pulleys....................................................11
Disassembling the Drive Pulley.......................................................................12
Reassembling the Drive Pulley........................................................................15
Disassembling the Driven Pulley.....................................................................17
Reassembling the Driven Pulley......................................................................20

2
Important Notice

Only qualified personnel can perform maintenance and repair operations on the variable
speed transmission system.

Means there is a risk of serious injury if the instructions are not followed as described.

Means that, when performing this step, there is a risk of damaging a part or of the
components malfunctioning.

CVTech is held harmless of any and all liability as concerns damage or injury resulting from
the incorrect understanding of the text, improper use of the transmission system, or improper
use of the recommended tools.

It is very important that you use the tightening torque indicated.

Maintenance Frequency

The transmission system does not require any lubrication. It is designed to work without
lubricants. Given this, you have to apply certain rules of cleanliness when handling the system
to avoid having any products come into contact with its components.


To increase the life of the transmission system, it is strongly recommended that you inspect
the following:

Description Inspection Maintenance Interval
Drive Pulley Visual / General Condition at 10 000 km
Fixed Sheave Visual at 10 000 km
Sliding Sheave Visual at 10 000 km
Assembled Centrifuge
Unit
Visual at 10 000 km
Lower Bearing Visual Replace at 10 000 km
Spring Visual at 10 000 km
Upper Bearing Visual Replace at 10 000 km
Driven Pulley Visual / General Condition at 10 000 km
Fixed Sheave Visual at 10 000 km
Sliding Sheave Visual at 10 000 km
Cam Fittings Visual / Dimensional at 10 000 km
Spring Visual at 10 000 km
Drive Belt Visual / Dimensional at 10 000 km
3

The Necessary Handling Tools







Torque Wrench Flathead Screwdriver
Pliers for Locking Ring removal


Pillar or Drill Press






3-Prong Extractor

17 mm and 30 mm Sockets









Hammer
* Pulley Disassembly
Tool (5055-0002)
Vise






Drive Pulley Extractor
(X-1720)
* Driven Pulley
Extractor (5055-0001)




* Tool available from CVTech

Important: Using impact tools is not recommended.
4

Transmission System Parts

The transmission system is made up of three main parts: the Drive Pulley (3), the Driven
Pulley (7) and the Drive Belt (10).





1...Flywheel
2...Gearbox
3...Drive Pulley
4...Lock Washer
5...Hexagon Bolt (retaining)
6...Pin
7...Driven Pulley
8...Lock Washer
9...Hexagon Bolt (retaining)
10. Drive Belt
5

Installing the Pulleys onto the Vehicle

Before you start:
The first time you install the pulleys on the vehicle, have the installation drawing handy.
This drawing includes all the vehicles specifications, Pulley and Drive Belt Numbers,
and the dimensional geometry for complete assembly.
Make sure all the components are clean.
Do not use any lubricants.

Installing the Driven Pulley

Mount the Driven Pulley (7) and the Drive
Belt (10) on the Gearbox Shaft (2). Make sure
you insert the Pin (6).












Installing the Drive Pulley and Belt

To allow for greater Drive Pulley and Belt mounting ease, a Spreader Screw, No. 0080-0055
(M6x1.0), may be used for spreading apart the Driven Pulley Sheaves, thereby reducing Drive
Belt tightness.

Mount the drive pulley (3) by passing it through the drive belt (10) and then mounting it on the
flywheel shaft (1).













6

Bolt Tightening

Once the Pulleys and Drive Belt are properly installed,
use a torque wrench (standard torque) to tighten the two
bolts.

Nominal Bolt
Diameter
Grade

Standard Torque
(Newton meters)
8 mm 8.8 21 to 28
10 mm 8.8 42 to 54

To tighten the Drive Pulley, use a screwdriver or other
tool to block the engine from turning. Be careful not to
damage any of the parts.


Do not forget to remove the Driven Pulley Sheave Spreader Screw. If this is not done, the
Pulley may become unbalanced.
7


Removing the Pulleys from the Vehicle



Before disassembling the Unit, identify Drive Belt Rotation Direction
so that it will be the same when assembling.











Remove the bolt (5) from the drive pulley and
the bolt (9) from the driven pulley.










Remove the Nut that holds the Drive Pulley in a closed position.
(use a 30 mm Socket)









Make sure you dont drop the cap and the units.
(It is safer to remove the loose parts, that is, parts that are no longer attached.)





8

Use Drive Pulley Extractor X-1720, and, if need be, Driven Pulley Extractor 5055-0001 (it is
possible to manually remove the Driven Pulley).





















For the Drive Pulley:
Insert the X-1720A Extractor Rod into the
Drive Pulley Shaft and bolt the X-1720C Adaptor to
the end of the Drive Pulley Shaft. (Using pressure,
turn one half turn)

Though not recommended by CVTech,
sometimes, tapping the extractor gently with a
hammer can help free the shaft of the drive
pulley from the flywheel.


For the Driven Pulley:
Bolt Adaptor 5055-2002 inside the
Driven Pulley Shaft.








Turn the Extractor Bolts until the Pulleys
move away from their position.
9

Drive Belt Inspection


The Drive Belt must be inspected in order to avoid damage that might cause
bodily harm and/or material damage.



The Drive Belt must be replaced if cracks are seen in it when it is turned inside out.












The Drive Belt must be replaced when its width becomes 28.5 mm. In other words, about
2 mm narrower than a new one.




10

Disassembling and Reassembling the Pulleys



The Drive Pulley





1....Fixed Sheave
2....Space Washer
3....Sliding Sheave
4.... Lower Bearing
5.... Space Washer (2 mm)
6.... Space Washer (1 mm)
7.... Space Washer (0.5 mm)
8.... Spring
9.... Space Washer (1.21 mm)
10.. Space Washer (0.68 mm)
11.. Upper Bearing
12.. Retaining Ring
13.. Weight
14.. Centrifuge Unit
15...Assembled Centrifuge Unit
16.. Cap
17.. Flat Washer
18.. Nut
19.. Lock Washer
20.. Bolt (retaining)
11
Disassembling the Drive Pulley


Disassembling the Cap and Centrifuge Blocks

Remove the Nut (18) and Washer (17). The Cap and Centrifuge
Blocks are now free.

Recommended Inspection

Damage to the Centrifuge Blocks
Sheave wear (due to Drive Belt friction)





Disassembling the Sliding Sheave

Use of the Disassembly Tool 5055-0002 is a must in order to
make sure the Sliding Sheave does not come apart too abruptly
(spring effect).















Though not as safe, a Bench Press (refer to illustration) or Press Drill
may be used.
12
Once you have removed the Sliding Sheave from the Fixed Sheave
Shaft, position the Fixed Sheave onto the Disassembly Tool in order to
lower the Upper Bearing (11).












Lower the Upper Bearing (11) so you can remove the
Retaining Ring (12) with a Flathead Screwdriver.






By slowly raising it, the Sliding Sheave is now disassembled.
Be careful not to drop any of the parts when using a Bench Press.






Depending upon Pulley adjustment,
make sure you jot down the number and position of the Space
Washers (5-6-7) and (9-10) so that the original Pulley
performance is not altered.
For peak performance, make sure you clean the sliding parts with
a degreaser.


Inspection

Wear damage to Bearings 4 and 11
Sheave wear (due to Drive Belt friction)
Wear damage to the Spring (8)
13

Disassembling the Fixed Sheave (as needed)



1 Fixed Sheave
1a Bearing
1b Locking Ring









Before each part-removal step, make very sure you
clean the shaft well.





The use of an Extractor is necessary in order not to damage those parts that
do not require replacement.







Removal of the Locking Ring (1b)




Removal of the Bearing (1a)



Inspection

Shaft wear. (inside and out)
Sheave wear (due to Drive Belt friction)
Bearing replacement (1a), if required
14

Reassembling the Drive Pulley



Reassembling the Sliding Sheave

To reassemble the sliding Sheave, see the procedure Disassembling the sliding Sheave and
reverse the directions.

Make sure you put the spacing washers back in their original positions.


Reassembling the Fixed Sheave

For Sheave reassembly, the use of a Bench Press and Tube (32 mm inside diameter and 125 mm
long) is recommended.

Refer to the illustration:
- Insert the Bearing (1a).
- Insert the Locking Ring (1b).








Make sure the Shaft Shoulder, Bearing and Locking Ring make perfect contact with each
other. Do not use too much pressure with the press or you will damage the components.




Before mounting the Sliding Sheave (3) on the Fixed Sheave
Shaft (1), make sure you place the Space Washer (2)
on the Shaft.
15

Mounting the Sliding Sheave on the Fixed Sheave Shaft


Take care to properly center the Space
Washers (5-6 and 7) onto the Shaft when
assembling.







Mounting the Cap and Centrifuge Blocks

Mount the three Blocks as per the illustration.










Tightening the Pulley

Use a Torque Wrench and 30mm Socket to tighten the Pulley.

Use a tightening torque of 95 to
108 Newton meters.









16

The Driven Pulley


1.... Fixed Sheave
2.... Sliding Sheave
3.... Cam Shoe
4.... Spring
5.... Pin
6.... Cam
7.... Retaining Ring


Disassembling the Driven Pulley

Make sure you jot down the position of the Spring in the Sliding Sheave and Cam.
When reassembling the Pulley, the positions must be the same as during disassembly. This
ensures that Pulley performance is not affected.









17

Disassembling the Cam

Use of Disassembly Tool 5055-0002 is a must in order not
to disassemble the Sliding Sheave too abruptly (spring effect).













Adjust the Lock Screw in order to prevent the Pulley from
turning.




















Lower the Cam (3 to 4 mm maximum) in order to free
up the Retaining Ring.

Remove the Retaining Ring using the appropriate
pliers.

18



Slowly lift the Cam to free it from the Shaft.


Inspection

Wear damage to the Cam.
Wear damage to the Spring.
Visual inspection of the components.








Disassembling the Sliding Sheave


The Cam Fittings can be removed using a Flathead
Screwdriver.










Inspection

Cam Fitting (3) replacement must be carried
out when they are worn by half of the original
thickness (X)
Sheave wear (due to Drive Belt friction)
Wear to the Sheave Inside Bearings
(do not replace unless the Sheave shows wear damage)

For peak performance, make sure the Sheave Inside Bearings are cleaned with a degreaser.

19
Fixed Sheave
The Fixed Sheave (1) cannot be disassembled without damaging the parts. All one can
do is inspect it.


Inspection

Shaft wear damage (inside and out)
Sheave wear (due to Drive Belt friction)
Visual inspection.



Reassembling the Driven Pulley

Mounting the Cam Fittings onto the Sliding Sheave

Use a hammer to mount the cam fittings
(3).






Do not be too rough with the hammer. You might damage the Fittings.





Mounting the Spring onto the Sliding Sheave


Position the Spring (4) into the Sliding Sheave (2) into the
same
position as when disassembled.
Position the Pin (5) onto the Fixed Sheave Shaft (1).


20

Mounting the Cam

To mount the Cam (6), use the disassembly procedure in reverse.


21
bled.
Place the Spring into the Cam in the
same position as when disassem
Glide the Cam (6) onto the Fixed Sheave
Shaft (1) and Pin (5) at the same time.

With the Fixed Sheave (1) rotation
blocked, turn the Sliding Sheave (2) one
third (1/3) of a rotation counter
clockwise.

Lower the Cam (6) to set it onto the Cam
Fittings (3).

Install the Retaining Ring (7).