All sorts of messed up

[Rhodie]

Sup guys, recently installed a polini variator and malossi belt into my af05e. Install went smoothly and the bike started and rode. Next day I went to start the bike and gas started leaking from this hole under the case that's near the gearbox. Anyone know whats up with that? Also went to swap variator weights and noticed that the boss is stuck on the crank. It can slide back and forth but it's blocked by the splines that seemed to have mushroomed just enough for it to block in the boss. What should I do about that? https://youtube.com/shorts/qZNQXLRrqV0 https://youtube.com/shorts/u_5rZi2XGgM

[bonesv]

Ouch! That hurt just watching you! That boss seems to be longer than stock - so now you have very little left of the splines to hold the drive face onto the crankshaft. DANGER!!! Do Not Ride It Like That! I know you are being very careful with this situation so maybe you can try to file the splines that are not being nice just a tiny little bit and to get the boss to slide off easier, try using a propane torch to carefully heat just the outer side of the variator boss. Just enough to expand it over the splines and you can go back and clean them up after it is out of the way It appears that maybe you are using a Polini boss? That might not be a good fit for your motor, just use the stock one or evenly grind off some of that Polini boss to give you more splines. But It Is Crucial To Do This Very Carefully and don't over-tighten the nut -that will be bad also

[ntonar]

The leaking gas is probably a bad float needle/petcock. Did you run the stock boss?