DSCF0039~1.JPGSlide on the rear pulley1469 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.JPGFront fastenings434 viewsSlide on the two washers making sure the convex one is the right way round
DSCF0044~0.JPGCheck the belt424 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.
DSCF0032~0.JPGFirst slide on the spacer356 viewsInner chamfer towards the engine as shown is extremely important!
DSCF0056.JPGFit the outer trim cover348 viewsA spot of coppaslip on the screws prevents them seizing.
DSCF0036~0.JPGRear pulley needle bearings334 viewsApply some LM grease to the inner bearings of the rear pulley. Not too much but enough to fill the cavity inside the sleeve.
DSCF0030~0.JPGRear pulley assembly315 viewsImportant to be scrupulous with old dust removal especially in the split between pulley halves
DSCF0038~0.JPGDirection Arrows309 viewsMake sure you get the direction arrows pointing correctly in the direction the belt rotates (top forward)
DSCF0024~0.JPGEmpty transmission casing231 viewsAll cleaned out of old belt dust ready for reassembly
DSCF0037~0.JPGEngage the belt into the rear pulley219 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.
DSCF0055.JPGRefit the 8mm bolts 208 viewsA touch of coppaslip helps future removals here
DSCF0061.JPGPut all the panels back on208 viewsJob complete. Now test run just to make sure everything is OK.
DSCF0043~0.JPGFit and tighten the nut195 views
DSCF0052.JPGRefit the two washers and rear hub nut190 viewsNip up the nut while holding the rear brake on.
DSCF0025.JPGVariator parts165 viewsCleaned and ready for refitting after examination wor wear
DSCF0050.JPGFit the clutch drum165 viewsLightly grease the shaft and slide the drum and then the spacer washer onto the rear shaft.
DSCF0054.JPGRun the engine again.158 viewsRun the engine through a series of rev cycles to make sure the belt and rollers are all settled and the gearing is functioning as it should. Recheck the nut torques.
DSCF0058.JPGRefit the air dflector158 viewsThis little gizmo is why the footboard has to come off on an Evo as you can't get to the mounting screws.
Most viewed - 500 Evo belt change
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