X9 Owners Club Gallery

Scooter related interest

Home > Maintenance > 500 Evo belt change

500 Evo belt change
DSCF0024~0.JPG
 DSCF0024~0.JPGEmpty transmission casing221 viewsAll cleaned out of old belt dust ready for reassembly
DSCF0059.JPG
 DSCF0059.JPGLower screw position147 viewsWhy the belly pan has to be eased down to get to the screws
DSCF0025.JPG
 DSCF0025.JPGVariator parts160 viewsCleaned and ready for refitting after examination wor wear
DSCF0030~0.JPG
 DSCF0030~0.JPGRear pulley assembly309 viewsImportant to be scrupulous with old dust removal especially in the split between pulley halves
DSCF0032~0.JPG
 DSCF0032~0.JPGFirst slide on the spacer353 viewsInner chamfer towards the engine as shown is extremely important!
DSCF0033~0.JPG
 DSCF0033~0.JPGVariator is slip into place145 viewsHaving dropped in the rollers and the ramp plate hold in position and slide onto lightly greased shaft
DSCF0034~0.JPG
 DSCF0034~0.JPGSPacer Tube128 viewsSlide the spacer tube into place with a tiny smear of copper grease
DSCF0035~0.JPG
 DSCF0035~0.JPGSlide on the spacer135 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.
DSCF0036~0.JPG
 DSCF0036~0.JPGRear pulley needle bearings329 viewsApply some LM grease to the inner bearings of the rear pulley. Not too much but enough to fill the cavity inside the sleeve.
DSCF0037~0.JPG
 DSCF0037~0.JPGEngage the belt into the rear pulley211 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.
DSCF0038~0.JPG
 DSCF0038~0.JPGDirection Arrows301 viewsMake sure you get the direction arrows pointing correctly in the direction the belt rotates (top forward)
DSCF0039~1.JPG
 DSCF0039~1.JPGSlide on the rear pulley1295 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.
DSCF0041~2.JPG
 DSCF0041~2.JPGFront fastenings430 viewsSlide on the two washers making sure the convex one is the right way round
DSCF0043~0.JPG
 DSCF0043~0.JPGFit and tighten the nut190 views
DSCF0044~0.JPG
 DSCF0044~0.JPGCheck the belt418 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.
DSCF0048.JPG
 DSCF0048.JPGRefit the damper pulley142 viewsLightly grease the pivot bolt and refit the pulley noting that it is the correct way around.
DSCF0049.JPG
 DSCF0049.JPGStart the engine139 viewsRun for only a few seconds just to settle the belt into the normal tension.
DSCF0050.JPG
 DSCF0050.JPGFit the clutch drum159 viewsLightly grease the shaft and slide the drum and then the spacer washer onto the rear shaft.
27 files on 2 page(s) 12