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500 Evo belt change
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 DSCF0024~0.JPGEmpty transmission casing161 viewsAll cleaned out of old belt dust ready for reassembly
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 DSCF0059.JPGLower screw position109 viewsWhy the belly pan has to be eased down to get to the screws
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 DSCF0025.JPGVariator parts122 viewsCleaned and ready for refitting after examination wor wear
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 DSCF0030~0.JPGRear pulley assembly271 viewsImportant to be scrupulous with old dust removal especially in the split between pulley halves
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 DSCF0032~0.JPGFirst slide on the spacer108 viewsInner chamfer towards the engine as shown is extremely important!
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 DSCF0033~0.JPGVariator is slip into place109 viewsHaving dropped in the rollers and the ramp plate hold in position and slide onto lightly greased shaft
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 DSCF0034~0.JPGSPacer Tube92 viewsSlide the spacer tube into place with a tiny smear of copper grease
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 DSCF0035~0.JPGSlide on the spacer92 viewsSometimes called the 'fuzzy washer' and a thicker one lowers the gearing. Never try leaving it off or the outer pulley gets stuck solid on the shaft.
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 DSCF0036~0.JPGRear pulley needle bearings293 viewsApply some LM grease to the inner bearings of the rear pulley. Not too much but enough to fill the cavity inside the sleeve.
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 DSCF0037~0.JPGEngage the belt into the rear pulley119 viewsPlace your foot on the top of the clutch and squeeze the upper pulley towards you by rotating it, and engage the belt as deep as possible.
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 DSCF0038~0.JPGDirection Arrows110 viewsMake sure you get the direction arrows pointing correctly in the direction the belt rotates (top forward)
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 DSCF0039~1.JPGSlide on the rear pulley107 viewsAvoid getting greasy fingers on either the belt or the pulley sides when assembling, although it will soon wear off and be no long term problem.
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 DSCF0041~2.JPGFront fastenings106 viewsSlide on the two washers making sure the convex one is the right way round
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 DSCF0043~0.JPGFit and tighten the nut101 views
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 DSCF0044~0.JPGCheck the belt110 viewsMake sure the belt is not nipped by the pulley halves and that the torque on the nut is fully used to force the outer pulley onto the spacer tube and washer.
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 DSCF0048.JPGRefit the damper pulley105 viewsLightly grease the pivot bolt and refit the pulley noting that it is the correct way around.
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 DSCF0049.JPGStart the engine105 viewsRun for only a few seconds just to settle the belt into the normal tension.
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 DSCF0050.JPGFit the clutch drum123 viewsLightly grease the shaft and slide the drum and then the spacer washer onto the rear shaft.
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