DIY - CVT Special Tools

CVT Special Tools

A number of special tools are needed to remove the CVT assembly from the engine and to crank it open.

The focus of this DIY is to demonstrate the alternate home grown tools besides those offered by Suzuki at exorbitant prices.

Use the information about these homemade equivalent tools at your own risk as there are no guarantees to back them up besides the resolve of those that have tried and used them to repair their CVTs.

Each tool will have its own separate section with accompanying pictures and videos to document and demonstrate them in actual use.

CVT Guides

The CVT Guides are used to separate the CVT Assembly from the engine.

They are steel rods that bolt onto the engine and help hold the CVT up as it is separated from the engine.

09920-31050 CVT Guide

You can purchase the OEM CVT Guides from any OEM parts vendor.

The dimensions of the Guides are as follows: M10 x 1.25 x 30 cm or M10 x 1.25 x 12 inches

You can try and purchase metric bolts with that match the CVT Guide dimensions. They will need to be at least 10” long.

Another option is to fabricate your own from steel rods and use a die/tap tool to cut the proper threads.

I opted to fabricate my own, as I could not locally locate any bolts long enough to be useful. It was also a lot cheaper to just buy a 3 feet long ⅜” steel rod for $5.00, cut it into three 12 inch rods and thread one end on each rod.

You will need a threading tool to make your own so keep than in mind as far as cost is concerned

Another alternative is to use the Engine Mounting Bolts that came off the scoot during the engine / frame separation. I chose not to use those as I did not want to run the risk of bending them and have to pay Suzuki prices to replace them.

I purchased a Tap & Die set from Harbor Freight for $12.00 on sale which had an M10 x 1.25 cutting tool and a thread pitch gauge.

Here is my tools list for fabricating your own CVT Guides:

Materials

3 feet long 10 mm or ⅜” steel rod
Cutting oil or generic oil/lube

Tools

Threading / Cutting Tool M10 x 1.25
Thread Gauge
Vise

Step	Guides Fabrication
1.	Cut the steel rod into three 12 inches long rods.
2.	Clamp a cut rod inside a vise. Make sure that the rod cannot move inside the vise.
3.	Assemble your threading tool.
4.	Oil the top of the rod inside the vise. Place the cutting tool over the rod and being threading. I found that small cuts were the best way to proceed. Two tugs forward and one back to clear the shavings. Use plenty of cutting oil/lube after a few strokes. Lay a ¾ inch thread at one of the rod.
5.	Repeat steps 1-4 for the other two rods.
Tip:	I used an M10 x 1.25 nut to make sure that each threaded rod could thread on and off flawlessly. Also double check for any loose play, there shouldn’t be any.

CVT Secondary / Primary Pulley Shaft Holder

The CVT Secondary / Primary Pulley Shaft Holders are used to immobilize the shaft while undoing the nut / bolt.

09920-31030: CVT Secondary Pulley Shaft Holder

09920-31010: CVT Primary PUlley Shaft Holder

Buffalo on BUSA came up with the pefect solution for a home made DIY tool alternative, a pipe wrench.

Buffalo took the time to measure his tool and forwarded the following measurements to me which helped me in

locating one at Harbor Freight for $6.00.

You basically want a pipe wrench that has about 8 teeth per inch, those measurements fit both the primary and secondary shafts perfectly.

Here are a few pictures to show the DIY tool in action:

CVT Primary Pulley Shaft Adapter Remover

09920-31040: CVT Primary PUlley Shaft Adaptor Remover

The special tool from Suzuki costs about $43.00 and is on back order in the US, at least it was when I tried to purchase one.

farqhuarforever from BUSA suggested using the rear wheel axle, which seems to be the same size and have the same thread pattern as the special tool to remove the primary shaft adapter.

I used the small bearing puller from my Harbor Freight set to remove the primary pulley shaft adapter.

Puller Bearing Separator Set

You will have to use a bearing puller to remove the secondary pulley shaft adapter. I opted to use a bearing puller instead which provides a more stable platform to work with as the regular 2 or 3 jaws pullers can slip and you will have to contest with the shaft rotating around on you.

I purchased my puller set from Harbor Freight on sale for $32.00.

CVT Crankcase Separating Tool

09920-13120: Crankcase separator

Extension Handle

I opted to use an impact gun instead of an extension handle mainly because it was much easier to apply the proper amount of torque to remove the pulley adapters. The Extension handle was also awkward to use as it forced the

pulley shaft to spin.

09920-31020: Extension Handle

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