For those who helped w/ my "hardshifting" Aero...some pics

[caddyss]

So I took the advice to check out the clutch assembly in my Aero 50 that "shifts" hard from a stop, and here's what I found. I decided to take off the movable drive face assembly as well (where the 6 little weight rollers are), as long as I was in there anyway. I'll start with the clutch: as you can hopefully see, the little springs with the clutch shoes look pretty good and tight. Also, the large spring inside the clutch measured at 3.75", which is within the service limit. The clutch shoes themselves were almost exactly 2mm, which is what the service limit is. Could that be my problem? Also, they were really smooth and I'm not sure if that's normal. I put new grease where the little guide roller pins go inside the movable driven face because it was pretty nasty in there. I've been told that if they don't move freely it can cause bad or harsh "shifting".

But what really surprised me was when I checked out the movable drive face assembly....as you can hopefully see in the pics, they were just packed with black "sludge". Not sure if it was original bearing grease or what, but it was pretty tacky and everywhere. I'd be surprised if those rollers could move much. Another thing I noticed was that each of the rollers had a very very slight flat spot, can barely feel it. Is that normal or is it a problem? Do I need new rollers? After cleaning, I also took a pic of the assembly where they would normally sit. The pic looks like its worn there, but its completely smooth. Also, when I reassemble this with the rollers, should I grease the entire inside, or only where the rollers go? I just plan on using Lithium bearing grease.

Any opinions on whether any of this would cause the jolt when I leave from a stop? Thanks for your help and any replies.

Dave

[Rip_City_Spree]

I don't grease my rollers and don't know many who do. I'd clean that up and check to make sure nothing is leaking out of the case. That looks nasty in there and shouldn't. And if you roll your rollers on a flat surface and there are noticeable flat spots you should get new rollers. Was it like that in the last pic when you took it off?

[Meatball]

Flat spots are a sign that they need to be replaced. Rollers are cheap enough that it wont break the bank but certainly don't get junk generic ones. Grease has no business in this area and SOME people recommend to rub the rollers with Graphite Powder. Also called Graphite Lube. Usually comes in a tiny tube and the fine black powder resembles pencil lead dust. It should be applied sparingly as not to leave excess powder fly everywhere when spun at high speeds.

It seems to be debatable if the graphite lube is even necessary. Some say yes, some say no. I run mine clean and dry without issue. I think grease is applied as a Band-Aid fix when your rollers begin to flat spot and don't roll anymore. A feeble attempt to get more miles out of them by trying to get them to "slide" rather than "roll".

Judging by the marks left by the rollers on pic #1...looks like they have been "sliding" for quite some time.

[MrJumps]

Get some rollers, no grease go dry make sure your variator is together tight Nd you shoukd be set. Your clutch pads look okay for a good bit more driving if your really woried about it rough them up a bit with some sand paper. They get glazed over time especially if taking off alot quickly. My old spree clutch was the same. Hit it with sand paper and it was fine, just dont get grease on the pads. Brake cleen them off good afterwards and you should be good to go. Idk what the stock weights for the variator were but maybe consult the manual sometimes they list that stuff. But yeah rollers, rough uo the pads, maybe new pads down the road another 500-1000 miles?

[eclark5483]

You'd think for the price of rollers and the effort involved into reaching them in the first place, that one would just replace them rather then grease them. People are strange....

[eclark5483]

As for the clutch, if it's JUST AT spec, you might wanna consider getting it repadded.

[caddyss]

Yeah that last pic is what it looked like when I opened it...that's why I was saying I was surprised. Thanks for the tips guys. Anybody know the stock weight for the rollers? I think its 10g but can't find it in the manual. And maybe a good place to order them? I'd like to stay away from the crap "generic" ones you mentioned but have no idea how to tell.

Thanks,
Dave

[ped]

hi sounds like the grease is causing slippage on the rear clutch. You have to clean all the grease out and possibly replace the rear clutch. Gl

[MrJumps]

Well bonesv on here has access sometimes to good used or oem parts, graphite9 has performance parts off hand, and a few others ive never delth with have som parts laying around. Post an ad in the wanted section. You may also have to get your hands on a gram scale incase no one has the stock weight for you. They arent too pricy and if you plan on ever doing a upgrade or other activities that involve a gram scale like cooking then you already have one. Also grease is only needed on the rear pully pins, and maybe the brake arm pivot. But besides that honda slathered grease everywhere when they made these bikes.

[caddyss]

After adding new rollers, some sanding, and cleaning, etc...the hard "shifting" seems to be gone. Must have been the rollers.

Thanks for all the advice!
Dave