Free printableComplete packsTSP-PK-05FLAGSHIP
The CVT Overhaul Pack
Diagnose it, measure everything that comes out, and record what goes back in. Four sheets for the system that wears fastest.
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13 pages. No account, no sign-up, no newsletter. Print it, copy it, hand it to somebody else.
TSP-PK-05 · version v1.0 · September 2026. Opens in your browser's PDF viewer, where you can print directly.
The sheets inside this pack
Every one is also available on its own, free. The pack exists so you can print once rather than 4 times.
The problem it solves
A transmission overhaul on these machines is usually done by replacing everything inside the case at once. It works, and it teaches you nothing — so when the same symptom returns in eight months, you replace everything again, and you still do not know what the belt in there is or what the rollers weigh.
The CVT contains the fastest-wearing parts on a scooter and the ones most often replaced with something different from what came out. It is also the system with no dipstick and no warning light, so it gets attention only once it squeals.
This pack covers a whole overhaul in one print job: work out what is actually wrong before opening it, measure everything that comes out at true size, and record what goes back in with its measurements so the next service starts from evidence.
Do that twice and you have your own wear rates — how many miles your belt lasts, how quickly your rollers flatten. That number is worth more than any published interval, because it is about your machine and the way you ride it.
The mistakes this sheet exists to prevent
- Fitting a new belt into a case contaminated with oil, which glazes the new one within weeks.
- Replacing the belt without checking the clutch, which glazes and causes the same symptoms.
- Binning the old rollers without weighing them, losing the only record of how the machine was set up.
- Ordering a belt by engine size rather than by case length and measurement.
- Cleaning friction faces with something that leaves a residue, which makes the slip worse.
Who it is for
- Anyone about to open the transmission for the first time
- Owners with a slipping, juddering or squealing CVT
- Anyone who has changed roller weights and wants to know whether it helped
What is on it
- The slipping, judder and squeal diagnostic with a full cover-off inspection list
- Belt measurement with true-size width bars and the marking convention explained
- Roller measurement with true-size diameter circles and a per-roller weight record
- A service record that builds your own wear rates over time
How to use it
- 01Diagnose before you open it. The symptom sheet is first for a reason.
- 02Check the calibration rule before measuring against any printed scale.
- 03Measure and weigh the old parts before they go in the bin — that is the whole value.
- 04Keep the service record with the machine and fill it in every time the cover comes off.
Use it with the registry
Other sheets you may want
- GY6 CVT slipping, juddering and squealingThree different noises from the same case, and they mean different things. What to look at with the cover off, in order.
- CVT service record for a GY6 or Chinese scooterThe transmission is the highest-wear system on a scooter and the least documented. One sheet for everything that goes in it, with the measurements taken each time.
- GY6 belt size chart and measuring sheetHow to read the three numbers printed on a scooter drive belt, how to measure a belt that has no readable markings left, and a record sheet for the one you have.
Free to print, copy, and share — including in forums, clubs and workshops. If you find a mistake on this sheet, tell us and it gets corrected. Quote TSP-PK-05 and the version so we know exactly which sheet you mean. All printables.