The primary variator is mounted directly on the engine’s output shaft and is responsible for transferring power from the engine to the belt, which then drives the gearbox, drive shafts, and finally the wheels of your microcar. If it is worn, you may experience jerky driving, poor acceleration, or high engine revs without an increase in speed. Here we will go through how you can easily replace the variator yourself on microcars such as Ligier, Microcar, Aixam, Chatenet, and Casalini.
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Equipment required
- Torx key
- Flat screwdriver
- Open-end wrench
- Hammer
- Lashing strap or rubber band to hold the air filter in place
- Protective gloves
Time required
Approx. 30 minutes
Step-by-step: How to replace the primary variator (variator mounted on the engine)
1. Clear the working area
- Open the strap that holds the air filter box.
- Lift the air filter upwards towards the windshield.
- Secure the air filter in the raised position with a strap or string.
2. Remove the variator
- Unscrew the bolt that holds the variator in place (tightening torque: 70 Nm during reassembly).
- Block the variator with a flat screwdriver to prevent it from rotating during disassembly.
- Place the open-end wrench on the hexagon of the variator.
- Gently tap the wrench with a hammer to release the variator from the cone.
- Remove the variator from the drive belt and take it out completely.
3. Install the new variator
- Place the new variator on the engine shaft.
- Make sure it fits correctly into the cone before tightening the bolt.
- Reinstall the bolt and tighten it to 70 Nm.
- Lower the air filter back and fasten the strap again.
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