• Never grease the bolt, always remove all grease residues before mounting the J.Costa variator.
  • Never discard washers that come with the original variator. 
  • Tighten the crankshaft nut to the tightening torque recommended by the vehicle manufacturer, always using a torque wrench and never a pneumatic gun.
  • With the 125/150 Honda always mount the 150cc injection belt.
  • The belt always has to be the original, or in its absence the J.Costa
  • Always use the rear pulley, the spring and the original clutch.
  • If the kit contains a bolt, it must replace the bolt of origin, if the original is not to be mounted.
  • If the kit contains a washer this has to be mounted between the bell and the crankshaft.

It’s very important that the variator has a correct maintenance. In every servicing, the from that is at the end of this booklet, should be filled out 

The body of the variator, if the mounting and the maintineance is properly done, it has 2 years warranty. The rest of the components (slider, bushing, bell and weights) are consumables, so they should be remplaced at the end of their life.

In order to avoid technical problems, we recommend doing the mounting on an authorized mechanical store in order to assure a correct mounting.

We also recommend that in every time you do the oil check, check the variator in order to see the status of the weights, bushings, sliders and the belt.

It is necessary to change the weights when you feel that the engine is going at high RPM and the scooter is not moving accordingly.

If there’s movement between the slider and bushing, more than 0,2mm, the bushings needs to be replaced in order to achieve again the full performance of the variator.

  • The Yamaha T-Max must be removed before the variator nut is loosened.
  • Once the cover is removed loosen the nut take out the original variator and install the J.Costa. Fit the spacer and tighten the nut to 160Nm, blocking the drive with the Yamaha tool. Replace the cover.
  • If performance is increased will the engine suffer? Not because we do not modify the engine at all, we are simply able to transmit power to wheel better.
  • Anyway, all the engines have ignition cut and / or injection cut that protects them in case of excessive turns. For this case we have a ceramic additive that is fitted in the engine crankcase and transmission reduces friction, increasing the engine in smoothness and reducing wear.
  • Can I mount the variator? No, it is always advisable to install the inverter by a specialized workshop, as it is essential to respect the tightening torque recommended by the motor manufacturer.
  • More acceleration
  • Greater means
  • More speed up
  • Increased recovery
  • More power to wheel
  • Less vibration.
  • The design of the bell and how the masses slide on it, allows to increase the number of marches.
  • We have a shorter first at low laps (better acceleration).
  • We have a longer sixth, when the drive is fully open (closed pulley).
  • The power to wheel increases to any regimen, especially in the range of low and means, allowing great accelerations.
  • This happens because we are able to always drive the motor in the maximum torque range.
  • With the traditional variator, you can hear the typical bell of the rollers hitting the ramp.
  • With the J.Costa variator the engine becomes more pleasant, smoother and quieter.
  • Our J. Costa variator has no internal friction, which allows a better gas feel and better response when compared to the traditional variator.
  • When there is no physical contact between the bell and the variator, it allows the pulley to react immediately, when opening or closing the gas control.
  • In the traditional variator, the movement of the bell is mechanically guided, so the friction is greater and has a negative influence on the system response.
  • Because the pulley is self-centered with the bell.
  • Because the J.Costa variator is the only variator in the market that allows you to increase performance across the power range of the engine.
  • With the traditional system if you need more acceleration you have to lower the weight of the rollers. This implies that you need more engine revolutions to start moving and you lose speed.
  • With the J.Costa variator you will always have better accelerations without depending on the opening of the gas handle.
  • With the J.Costa variator you never lose top speed.
  • With the traditional variator it is necessary to change the rollers when they are no longer round or / and begin to be flat.
  • Using the variator J.Costa, the rollers need a period of adaptation, during that period the rollers can suffer a small wear. This wear is absolutely normal.
  • It is necessary to change the masses when the user feels that the motor rotates at high revolutions and the motor does not push.
  • The durability of the rollers:
    • For the T-Max and Maxiscooters can vary between 15,000 and 20,000 km (each change of belt).
    • For Megascooters between 10,000 and 15,000 km
    • For the 125 to 250cc between 6,000 and 10,000 km.

But it always depends on the driving style.

Assembly instruction

[flipbook pdf="http://www.jcosta.com/wp-content/uploads/2017/05/MOUNTING-INTRUCTIONS-ESP-EN-FR.pdf" height="501"]

J.Costa mounting and dismounting

J.Costa Official