Ok ok ok...we decided to adjust the clutch on my buddies 650 on Friday. All I can say is that I am a jack-*** for not doing this sooner. We bought what we needed to make the compressor tool, it was a walk in the park. I am kicking myself that I didn't do it sooner. It took us 50 mins to do it without any idea of what was gonna happen. Next time will certainly only take about 30 mins. Oh well, I have another 3 650's to play with later anyway. Thanks to Nyroc and all that helped, I printed out everyones posts and directions and it helped a great deal.

I noticed in the Kawi manual it describes adjust belt and it said 'remember, less (tightness) is more and that a tight belt will wear out faster'. Seems to me that they have it backwards, but WHY would the Kawi engineers be backwards? I'm sure they know it inside and out, just as much of us known our own.

Anyways, I'm gonna throw the new belt on with no shims in the secondary and see how that does. Hopefully will be ok. What is everybody using to apply pressure (13 lbs) to the belt to check the deflection? Anyone have any inovative ways of doing this easily?

 

I have a 12 lb dumbell. I lifted it with my thumb and then pressed that hard on the belt.
It is not hard at all for my thumb, but it is a serious strain for my pinky (I am a 200lb pencil pusher, not a cow milker).

Find a bathroom scale or a produce scale at the grocery store and push til you see 13 pounds. Remeber the feeling.

Other than using a finger to push, I didn't see any easy way to push on the belt.

 

There is a very easy way to find the exact belt deflection....
You just have to take a fish scale 0 to 20 pouds (don't take the one for the baracuda)

 

A fish scale will get you close enough, as mentioned earlier.