Homemade belt removal tool

rancher12 · #1 05-24-2008, 01:35 AM

This is my firstpost, other than the Intro one, so here goes. I bought a outty 800 and have been assembling a trail tool kit. Mainly so I can change the belt if it breaks 100 miles from the garage. I keep reading where a metric bolt can be used to spread the sheaves on the secondary pulley. One post says M8x1.25x70mm. The next says M8x1.25~6inches long. I understand you need a good amount of threads, and the first inch or so should be smooth to push on the pulley. I bought a M8X1.25X70mm bolt today, grade 12.9, but it is no where near 6 inches, more like 3-4. Will this work or do I need to get a longer M8X1.25???

Thanks Josh

BrianE · #2 05-24-2008, 01:46 AM

The factory one is 4.5" on the threads. I suggest take it apart and pull the belt. So you have the procedure down and don't have a surprise in the field

Kraker · #3 05-24-2008, 09:28 AM

70mm is 2 3/4" which is long enough as long as it is threaded all the way

trailrider2 · #4 05-24-2008, 11:28 AM

Agreed, I carry one 70mm, I can get the belt off and still have a good 1/4" to spare.

I'm not sure if this has ever been discussed before but, on mine at least, while there is 3 holes only one is threaded. :2cent:

rancher12 · #5 05-24-2008, 08:38 PM

Great! Thanks for the info. I got a bolt with threads all the way to the head of the bolt. glad to hear it works, now to break down and buy a spare belt!!

Kraker · #6 05-24-2008, 11:10 PM

i wouldnt bother.Belt destructing is fairly rare on these unless you're doing something out of the ordinary,or if you're gonna carry everything like spare tires,axles,spark plugs,etc.,etc. You've probably been hearing too much "honda guy other brand hating talk",lol.

trailrider2 · #7 05-25-2008, 12:13 AM

Thats not true, my wifes 500 started to grenade when we were 4 hours from home. Luckily we were close to camp when it happened but I wouldn't have risked another day. This is OEM BTW, I'm sure less than 1500 miles.

Kraker · #8 05-25-2008, 01:03 AM

that dont just happen for no reason.

trailrider2 · #9 05-25-2008, 01:41 AM

kraked, I definitely respect your opinions but I can't explain it myself. Her belt got wet once many months before this happened. I have a good third more hours than she does and I retired my belt because of wear width. I now carry it as a spare. My belt has gotten wet as well. CVT covers have been upgraded since then but I see no harm in carrying an extra belt and a simple bolt to change it out if need be.

I agree it shouldn't happen but it could and does IMO. You never know. :2cent:

rancher12 · #10 05-25-2008, 03:15 AM

I've seen many a trip cut short because of a belt broke. I've seen 10 times more belts break than axles, or whatever. Spark plugs, belts and tire patches are a necessity 100 miles in the woods of WV. :2cent: