Rebuilding CVT+other mods - Falcon 100c

Hey guys
Just joined the forum. I have 2003 Falcon 100, it's a chinese (crap) scooter, 2 stroke 100cc air cooled. Anyway, my girlfriend is using it to get to work. few days ago it died. It need CVT rebuild. My plan is to replace the clutch, variator, variator plate, rollers, main spring. Want to get the best parts there are on the market. Now, because it is one of those chinese scooters i find it hard to find correct parts. maybe you guys could help me? spent whole two days on internet/ ebay etc and cant get right parts. What i'm looking for is:
VARIATOR - its 94mm diagonally and has 15 cutters (teeth), the flange size is 21mm out and 16mm in
CLUTCH - it's 110mm diagonally and bell is 112 diagonally (inside) and has 16 cutters (teeth). Preferably Malossi of Polini (speed), 3 shoe.
there are pleanty of 107mm clutches but i beleive it would not fit my bell as is 112mm. Am i correct here? alternatively i could change clutch and bell for 107mm if i can't find clutch 110mm. but then how many cutters are there on 107mm bell?
I'm also not sure what kind of rollers and main spring should i put. i'm not that good with scooter tuning. i have off road buggy and run it on 12g rollers and yellow (2000rpm) spring. Not sure what set up would be the best for my scooter. Im looking for something in between power and speed.

do you guys know any places (websites) i could get the parts i need? i'm also open to any advices/sugesstions.
thank you in advance
tom

 

how come you gotta replace the variator ? they normally last quite a long time, usually just the rollers need changing and maybe the centre bush cleaning up...

im not sure where your gonna get aftermarket transmission components for a chinese bike :glare:

who makes the falcon 100cc ?

 

the vari needs change, it has extensive marks and snaps my belt quite often..
it is very unusual bike, no idea who makes Falcon 100 (i geuss some chinese ppl)

i beleive that soon i will also have to replace cylinder + piston. no idea where am i gona get parts from. I heard that cylinder would fir from Yamaha Aerox. Do you guys know by any chance what is the spacing between bolts on cylynder, and size of piston (mm)?
thanks

 

here's pic of my falcon

 

this is supposed to be aerox dimensions.


40mm piston.

 

hey thanks, but the pisc u attached shows water cooled cyliner, mine is air cooled. are dimensions in air cooled aerox the same?
thanks

 

can find kits for your engine but no dimensions, on the links page are some sites who you could e-mail for tech queries.

 

hey thanks, i have emailed more than 5 supliers already but no answere just yet. do you happen to know what are the size of variator in aerox? number of cutters etc? maybe it would fit mine too?

 

i have found a sinnis falcon and a baotion falcon scooter, but neither looks anything like yours...

if we can find out who makes it and what engine it has it will make it a hell of a lot easier finding parts...

if you google chinese scooters there maybe a helpful forum for chinese scooters...

 

hey dave thanks for trying. i could not find anything on internet. Even in my registration documents it only states Falcon 100. All engine parts are also marked with falcon logo/sign. i have tried chinese scooters forum as well but it seems that its not much happening on that forum. last posts from June.. i beleive that i can match some of the parts form other models. i have already sent more than 20 emails requesting sizes, dimetions etc. So far i have not got any answeres... seems that everybody is so rich that they dont want to make any business... i have cash waiting and dont care how much is it gonna cost. Oh well....