Ok I finally got my black spring in the mail and am in the proccess of doing the job via the NYROC website instructions (thanks NYroc!).

I measured my belts wear (Under 500 miles on machine, but now can't check actual miles since cvt covers off)
And it looks OK at the top edge- looks like 30.5 mm to me.

BUT when I measured the deflection I got a whopping 1 5/8"!
Is this possible/normal for a 2003 P-650?

Or did I measure it wrong?


Step 2 -"rotate pulleys to make sure belt is as far up on driven pulley as it wants to be."- isn't doing anything for me. Is this my trouble spot?

ThX

 

Dave (fellow Texan!),

I got your answer I hope. The belt deflection is supposed to be 22mm to 27mm (I readjusted my belt deflection this week). It is not uncommon for the belt to come very loose from the factory and won't take long to stretch way out of spec!

To properly check the belt deflection, I push the belt slack from the primary (ft pulley) towards the secondary (rr pulley) so that the belt is on the outermost edges of the secondary pulley. Then I spin the rear pulley one or twice so that it rides on the pulley naturally (but still on the outside edges). Be sure to apply about 12 or 13 lbs of pressure (I use a sm. fish scale) on the belt when measuring the deflection.

Good luck and happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

Thanks Mike, I tried the way you described and wound up with a 1 7/16" deflection. A little less than before, but still way off spec.
I guess I'm gonna be removing some shims along with the spring replacement.

Should I just wait until I get a new belt before going that far?

 

If you plan on riding it before the new belt arrives, I would recommend that you go ahead and reshim it (put a smaller size shim in) now. But you will probably have to do it all over when you put a new belt on...I assume you will be installing the P700 belt right? That is the best one to use on the P650 and its a tad bit wider than the P650 belt so it will probably add 1 mph to your top-speed.

I've found that once you tighted the belt a few times, its really not hard or timely to do.

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]

 

I replied yeasterday after I finished, but it didn't show up here?

Anyhow I finished the job, removed one of the two shims ( the thicker aluminum one) and wound up with a 15/16" deflection.

I took it for a spin and it will now pull wheelies a tad bit easier in low. I figured with the black spring and DG3 module I wouldn't be able to keep the front end down. Must be the front gear box and 26" muddruners weighing it down.

If I go with a 700 belt, would I need to add shims to make up for it being wider?

Thanks for the help Mike, DaveC

 

Yes, you might have to add a shim and/or insert a larger shim when you install a P700 belt. What I did was buy some extra shims at different sizes so that I am prepared to make any kind of adjustment (within reason). The only cost about $5 each at my local kaw. dealer. My P650 came with one .6mm shim and one .8mm shim. So I bought an extra .6mm shim and also a 1.0mm shim. Using these shims alone or in combo, now I can do any adjustment including .6, .8, 1.0, 1.2, 1.4, 1.6 and 1.8. Mostly, I have just used the .6, .8 and 1.0.

Happy trails...[img]i/expressions/face-icon-small-smile.gif[/img]