MOPED ARMY

Stock contra spring, 100mm pulleys on a Euro clutch. I haven't marked the variator cheeks but I can see it variating as far as it will go, if I set it up with much heavier weights it'll start to variate right as the clutches grab and won't let it pull high RPM. Right now it's variating through and still pulling a little more RPM after that.

something holding you back from getting to low 40's, don't think its the gearing,

I have a ciao with polini 63 kit including head, proma circuit exhaust, modified casings and crank, malossi variator and belt, 13 carb and I find that I can't go above a 60 jet in the carb, mine runs best with a 58 and I can get 38-40mph but it is screaming at that and you certainly couldn't hold it at those speeds for long without doing damage but I do find it's got good acceleration and plenty of power for hills and will cruise fairly comfortably at 33 though, I actually expected an easy 45 with that set up but there is no way it would ever get to that with standard gearing. I think a 70+ jet is huge for that set up and think you could possibly have an air leak somewhere, as I said mine runs best on a 58 with a 70+ it wouldn't even idle without having the screw nearly all the way in, the instructions for my kit states that it works best with jets between 52 and 56 and I find that a 58 just gives it a little more power without sacrificing top speed which to me that indicates my engine is working as it should and the fact you are on such a big jet further confirms to me you have a leak somewhere, most likely at the base of the barrel but other possible areas to check are the joint in the engine casings and the oil seal behind the points, I also had the same issue with the variator only going 3/4 of the way and I modified it so it now runs to the top but in all honesty I didn't think it made a noticable difference so I wouldn't blame that for now. I will be interested to know if you have managed to get any further forward with yours?

Have you tried lighter than 6g? You may still be over variating not letting it rev out

Yes I had to do the same on engine casings, as the area for gasket was so thin it would prob never have sealed. I think the over variation is possible too if still running the standard rear spring, I know with the malossi variator I got a yellow spring which is a fair bit stiffer than standard one and it came with 6g weights for that, although I do feel they were just slightly light prob 6.5g would be better

Update: finally took the variator apart, found out the brass bushing the pulley rides on seized, causing it to stay open. I pulled the clutch apart, replaced the pulleys with Treats' aftermarket set with the vented bushing. Replaced the clutch pads with a NOS Piaggio set and replaced the stock contra spring with a yellow Malossi piece. I was tired of dicking with old parts and basically just replaced everything.

Now when I try to put it on the bike it rubs straight on the frame, you can see in the pic where the back of the pulley is wearing a groove into the frame, and this is just from hand spinning the clutch. Apparently these pulleys are slightly different dimensions, am I unable it run these pulleys? Is there supposed to be a spacer or something in between the gearbox and back of the clutch unit to keep it from rubbing?

I've never genuinely hated a moped more than this one lol.

I shimmed out some 100mm cheeks on a ciao. I made a 13x10x1mm hardened washer. Goes on the rear shaft before the variator/clutch assembly goes on. 1mm spacing was just right.

If you can fit the shim down inside the variator it’s easier to install than putting it on the shaft first.

I'm having a hard time visualizing what you're talking about, do you have a pic? Are you saying that you put a spacer on the smaller diameter of the output shaft so the clutch assembly bottoms out 1mm further out from the frame?

Here's a pic of it ported out. I posted it before and everyone said it looked fine. This was just a pic of how wide I ported the window before I worked the inside wall for a nice smooth flow.

Regardless it doesn't matter atm as I'm trying to figure out how to get the euro clutch properly mounted to make it run at all lol. I think it may be an issue with the frame.

Just put a spacer on the shaft before the pulley, I’m running a Polini Variator that stuck out waaaay to far and had it machined down now it’s perfect. Same thing but diffren, use a spacer.

Concerning the rubbing issue, I had the same problem on my Grande and I recall missing some of the bearings on the chain side and it caused the wheel to flex on the hub. I ordered a new pack of bearings on ebay for cheap and just replaced them all Not sure of the size but I just used a caliper to measure and got it right. They are small and it took some time but fairly easy.