Ok fellas...I'm gonna try and do the deflection adjustment myself. 3 out of 5 650's (we ride together) are having similar problems although one is worse than the rest. We figure we might as well give it a shot instead of hauling them to the dealer.

When you pulled the shim, did you just remove the original and put the clutch back together or did you need to replace it with a smaller sized shim? How hard are the shims to get if you need a smaller one?

If anyone has any helpful hints and/or detailed instructions, feel free to let me know. I'm going to get all I can from Nyroc's site today.

 

Just be sure to use an impact wrencht to remove the 27 mm socket so you dont break it like I did. (See the what not to do on Nyroc's site) I don't have my service manual here at work, but it tells the relationship between shim thicknesses and how much deflection you will change. Once you get it off, it is cake.

 

My parts store had the shims in stock, I bought 3 of them (all different), but never used them.

I took my only shim out, and my first belt improved but still was loose and slipped.

I put a new belt on (no shims) and the new belt was .87 defelction. It squeaks at idle, but it is lasting longer, no slip, and it yanks a whole lot better at takeoff. Wheelies easier. Turns my big tires great. It has over 400 miles on the new belt, and it is not loosening up fast like the old belt (which was installed loose at the factory so it would not squeak).

If you are gonna guess, try no shims and the new belt. You may think it is too tight because it will drag a little in gear, but that will mostly go away after a good ride.

 

<< When you pulled the shim, did you just remove the original and put the clutch back together or did you need to replace it with a smaller sized shim? How hard are the shims to get if you need a smaller one? >>

I had to completely remove the shim to get it back into spec. Although, the deflection is still on the loose end at about an inch. Mine only had one shim in between; a 1.4mm one. I called my dealer to see if they had any of the smaller shims in stock. They said they had 2 of each so I drove 1/2 hour to find out that their stock report was wrong, they had none. They ordered them and later advised me that they are on backorder. I've been waiting a week now. It's a good thing I didn't need them.



<< If anyone has any helpful hints and/or detailed instructions, feel free to let me know. I'm going to get all I can from Nyroc's site today. >>



Nyroc's guidance has lead many of us to tackle this stuff by ourselves. However, feel free to take a peek at my instructions here http://pub96.ezboard.com/fatvwiscons...picID=11.topic

After adjusting my belt I now get a &quot;whine&quot; from the belt occasionally with it in gear at a stop. I guess I can deal with that knowing that the belt is tight at least.

 

The belts look and feel good (in good condition). Why would I need to replace it at 850 miles if it still looks in good condition? Would it be because of it stretching out?

Thanks for your help guys.

 

jlpeir01
I think it was a 27mm socket, is it not? (don't want anyone to go buy the wrong one)


I took out the stock shim and have the same squeal when stopped. My belt is still on the loose end of the spec. I am starting to wonder if using no shim is causing the squeal. I wonder if it requires at least one shim by design.

 

It is a 27mm socket.

Parker, a belt at 850 miles without being used a lot in mud with big tires probably has a little useable life left in it, more if it has been adjusted early on. But with so little life left, it is not worth it to get your last few miles out. I would replace it.

you can measure it to be sure. I would scan the manual to show you how to do it, but I might get Kawasaki mad at me.

Safest to replace the belt, if you are concerned about whether it is OK or not. Look at the wear face, if the teeth valleys stick into the wear face 1/16 or more, it is a goner. If they are even with it, may be some life left. Better to measure.

I am going to sketch up a picture of how to measure the belt, and post it on my website.

 

Hey, I just placed two sketches on my website, one of the deflection measurement and the other of the width measurement.

I drew them myself in Autocad, so I wont get busted by the copyright police.

 

Yep, I fixed it, sorry bout that. When it starts rounding the corners off you would figure it out LOL.

 

I had Kawi adjust my 650 today (we are going to do the other 2 quads ourselves). I just talked to the dealer tech. He said he took the shim completely out and it's all set. He said the belt is in rough shape and is at 27 mm (worn out according to Kawi's standard minimum of 28.8 mm). So the belt is worn and the friggin guy still puts it back together and says to ride it for another few hundred miles before it's totally gone. They just want to get me back in again to fork over more cash. This is ridiculous. If he had called me like he said he was going to, I would have had him order the belt and do it right.

These guys are idiots...Kawi should really do something about customer satisfaction. I saw a Kawi convention or something that Doug Meyers went to on ATV Television last night. We should have all met up at that convention, stormed the place and chained &amp; padlocked the doors shut. Then maybe they would have to listen to us. I would gladly pick up the bat and play Michael Douglas from that movie &quot;Falling Down&quot;.

So now I guess I'll just order a new belt and do it myself later on. I'll pick up some shims too, probably a few different sizes. Thanks for the help guys.