Benelli Pepe – de-restricting by removing the variator washer

Like many modern mopeds, the Pepe is restricted in three ways. It can’t reach top gear ratio because of a spacer washer, the fuel jet is undersized, and the exhaust has a restricted capacity section. This article just looks at the first one, which is easy to do (with the right tools), definitely works, and won’t affect how your bike looks. I used some pics of someone else for several of these, although these bikes are so similar it doesn’t make any difference. The variator picture is a Pepe.


 
First start by removing the socket head cap screws to remove the transmission cover on the left side of the scooter. There’s no need to remove the kick start – in fact it’s a bad idea because then the return spring might ping off, and it’s a devil to put back.

Watch for the length of bolts that come out, there are 11 that are 6mm head and one is much longer (the one in the middle of the cover). Then there are three more that are 8mm head. The topmost bolt retains an earth wire, so be sure to make note of this and remember to put it back on later. Also the very lowest bolt has a retainer attached which holds the rear brake cable in place. Again, take care to note how this goes so you can put it back correctly later.
Even with all the bolts removed, you’ll need to lever off the cover because it’s a tight fit. I found an edge near the top right corner where I could use a screw driver to do this. It is possible to wriggle the cover out from behind the air filter box on the left hand side, but it’s a bit of a fiddle. The alternative would be to remove all the plastic body panels to get the air filter off, and that wouldn’t be nice.
 
This is what you should have removed. This one’s from an Aprilla but the Benelli is very similar.

 
OK, now you should be looking at the whole drive train. As you face the open transmission, the variator is on the left, and the clutch is on the right. The nut on the variator is 18mm. To remove this nut, you need an impact wrench so you’ll probably have to hire one unless you know someone with one. HSS do electric ones for about £25 per day (2011). If you try to use a regular wrench on the nut, you will just rotate the pulley around, and not get anything done. You should get an impact socket (the black ones), don’t use a regular one because you’ll wreck it. So, if you get a half inch drive impact wrench, you want a half inch drive 18mm impact (black) socket. With these tools, the removal and replacement of this nut is dead easy. Without them, it’s a pig. The socket is not a regular automotive part, so you’ll probably need a specialist tool place to get one. I got one from Joseph Gleave for £4.
There’s no need to removed the 24mm nut on the clutch, that can stay where it is.

Once you have the variator off, you will notice a washer located between the two halves of the pulley. This is the restriction. That washer does not let the two halves come completely together, which prevents the scooter from going into its highest gearing. Removing it increased the top speed of my scooter from 40 to 50 Km/h.The washer was a monster on mine no wonder the thing was strangled! Also, you see the line in the picture? That’s the furthest up the gear that the drive belt had been able to ride with the washer in place – this is what we’re changing.
 
After the washer has been removed, re-assemble the variator onto the crank shaft. making sure the variator is all the way pushed to the back before tightening the bolt. The bolt must be impacted on.
Now all you need to do is put the cover back on. Make sure its fully seated because otherwise the kick start won’t be lined up properly with the crank
Job Done!