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The Scooter Parts Registry

Printable gauge

Variator roller sizing card

Rollers wear into a flat and lose their markings long before they are replaced. This sheet gives you the diameters at true size so you can identify what came out before ordering what goes in.

Set scaling to 100% or Actual size. Never “Fit to page”.

Variator roller sizing cardActual size. Place a roller flat on the circle it matches; check the width against the scale below.0102030405060708090100This bar must measure exactly 100mm. If it does not, reprint at 100% scale.Roller diameters — lay the roller flat inside the circle15mm16mm17mm18mm19mm20mm22mm23mm25mmRoller width — stand the roller on its edge against this scale10mm12mm13mm14mm15mm15.5mm17mm18mm20mmRollers are described as diameter × width, e.g. 18 × 14. Both must match. Weight in gramsis a separate tuning choice and is not a fitment dimension.thescooterparts.com — free to print and share. A measuring aid only: matching a dimension does not prove a part fits.

How to use this sheet

  1. Print at 100% and check the calibration bar measures exactly 100mm.
  2. Take the rollers out of the variator. There are usually six, sometimes eight. Clean the grease off them.
  3. Lay one flat on the sheet and find the circle it sits inside exactly. That is the diameter.
  4. Stand the same roller on its edge against the width scale. That is the second number.
  5. Check the rest. Rollers wear unevenly, and a set that measures inconsistently is a set that needs replacing regardless of what size it turns out to be.

What worn rollers look like

A healthy roller is round. A worn one develops a flat spot on one side and often a lip at the edges. Once flattened they no longer ride smoothly up the variator ramp, which shows up as hesitation getting away from a stop, a rattle from the transmission case at low speed, or a machine that will not reach the speed it used to.

Measure the diameter across the roundest part, not across the flat, or you will order a size down from what the machine actually takes.

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