Replacing drive belt

scubajoe · 07-19-2009, 10:33 PM

I've got an '87 2-stroke, which all of the suspension components were removed on by the previous owner, in order to lower it. I can't get the drive belt on without taking some stuff apart (I can't remember what I took apart last time). It won't fit between the end of the driven clutch, and the frame member. I can't see how the suspension would affect this spacing, but I'm not real sure what it look like stock.

I just want to confirm that I SHOULD be able to replace the belt without removing anything. I've been scratching my head over this for a while.

scottyb · 07-19-2009, 10:36 PM

Can you remove the bolt from your driven clutch and slide it out away from the frame enough to get the belt on?

scubajoe · 07-20-2009, 12:41 AM

Hmmm, I don't know. You mean the bolt on the end of the clutch? That might only work if the cap behind the bolt just slides off. Basically the belt won't slide under the clutch.

scubajoe · 07-20-2009, 12:50 AM

This is the clutch I have:

But the situation is kinda like here, where it needs to slide between the clutch and the frame, and won't fit.

dock98 · 07-20-2009, 10:27 AM

belt should slide between secondary clutch and frame.a little tight maybe but should still fit?

scubajoe · 07-20-2009, 11:16 AM

Yeah, I was guessing it *should* fit. Now I have to figure out why it does NOT fit. I suspect as soon as I get this cart running again, I'll have to sell it. Too much missing to get it back to stock without spending a large pile of cash.

scubajoe · 07-25-2009, 12:08 PM

There are two bushing where the frame connects to the engine mount. One larger one appears to be split around the middle, and I'm guessing was originally supposed to go on either side of the hole in the engine mount so that half of it sits on the frame and half sits above the engine mount, with a second bushing sitting on top of that, under the bolt. Looks like they were all installed, or got pushed through the hole, so they were basically created a larger space between the frame and engine mount.

I took the bushing out, and reinstalled them on top of the engine mount, and the belt now slides in, no problem.

07-19-2009, 10:33 PM	#1
scubajoe Getting Wild Join Date: Apr 2009 Location: NC Posts: 131	Replacing drive belt I've got an '87 2-stroke, which all of the suspension components were removed on by the previous owner, in order to lower it. I can't get the drive belt on without taking some stuff apart (I can't remember what I took apart last time). It won't fit between the end of the driven clutch, and the frame member. I can't see how the suspension would affect this spacing, but I'm not real sure what it look like stock. I just want to confirm that I SHOULD be able to replace the belt without removing anything. I've been scratching my head over this for a while.

07-19-2009, 10:36 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,418	Re: Replacing drive belt Can you remove the bolt from your driven clutch and slide it out away from the frame enough to get the belt on?

07-20-2009, 12:41 AM	#3
scubajoe Getting Wild Join Date: Apr 2009 Location: NC Posts: 131	Re: Replacing drive belt Hmmm, I don't know. You mean the bolt on the end of the clutch? That might only work if the cap behind the bolt just slides off. Basically the belt won't slide under the clutch.

07-20-2009, 12:50 AM	#4
scubajoe Getting Wild Join Date: Apr 2009 Location: NC Posts: 131	Re: Replacing drive belt This is the clutch I have: But the situation is kinda like here, where it needs to slide between the clutch and the frame, and won't fit.

07-20-2009, 10:27 AM	#5
dock98 doin it in the desert Join Date: Dec 2008 Location: Sonora Desert,Az Posts: 5,603	Re: Replacing drive belt belt should slide between secondary clutch and frame.a little tight maybe but should still fit?

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07-20-2009, 11:16 AM	#6
scubajoe Getting Wild Join Date: Apr 2009 Location: NC Posts: 131	Re: Replacing drive belt Yeah, I was guessing it should fit. Now I have to figure out why it does NOT fit. I suspect as soon as I get this cart running again, I'll have to sell it. Too much missing to get it back to stock without spending a large pile of cash.

07-25-2009, 12:08 PM	#7
scubajoe Getting Wild Join Date: Apr 2009 Location: NC Posts: 131	Re: Replacing drive belt There are two bushing where the frame connects to the engine mount. One larger one appears to be split around the middle, and I'm guessing was originally supposed to go on either side of the hole in the engine mount so that half of it sits on the frame and half sits above the engine mount, with a second bushing sitting on top of that, under the bolt. Looks like they were all installed, or got pushed through the hole, so they were basically created a larger space between the frame and engine mount. I took the bushing out, and reinstalled them on top of the engine mount, and the belt now slides in, no problem.

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