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Hi All, This might be a rookie mistake. I have just changed the drive belt and reinstalled the clutch bell and cover. After I torqued the nut down the rear wheel locks up.

However when loose the rear wheel spins freely.

I double checked the clutch nut to make sure it is not scrapping the bell.

The play on the spring on the clutch and the tension seems good

Maybe it is something on the drive end variator. I noticed that the belt is really tight on that end. Could be I am missing a washer?
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Are you putting the nut on before the belt cover? And there is a washer under the nut.
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Belt trapped between the Variator pulley halves when tightened down. See if you can turn Variator reasonably freely without out belt turning if held.
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grahamlml wrote:
Belt trapped between the Variator pulley halves when tightened down. See if you can turn Variator reasonably freely without out belt turning if held.
Shouldn't the rear wheel and clutch bell turn freely even if the belt is caught? Seems to me the problem is in the clutch.
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JKJ-FZ6 wrote:
Shouldn't the rear wheel and clutch bell turn freely even if the belt is caught? Seems to me the problem is in the clutch.
Now I had time to think properly you are right.
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kmev wrote:
Are you putting the nut on before the belt cover? And there is a washer under the nut.
Clutch Washer and nut are after I put on the cover on the outside of the bearing in the cover
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I'd suggest you take it apart again.
And this time, when assembling, do two things.
First, get the belt much deeper into the clutch before you put the clutch back on. The belt should be quite loose in the variator when you tighten that nut down.
Second, when you do put the clutch with belt back on, make sure there is nothing blocking it from being fully inserted onto the shaft.
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GTS4life wrote:
Clutch Washer and nut are after I put on the cover on the outside of the bearing in the cover
That's a thin washer, right? Not a 1/4" thick one? Some earlier models had such a washer and it had to go on the inside, between the bell and the cover. Later models had the equivalent thickness added to the bell.
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jimc wrote:
That's a thin washer, right? Not a 1/4" thick one? Some earlier models had such a washer and it had to go on the inside, between the bell and the cover. Later models had the equivalent thickness added to the bell.
Correct..there was no washer between the beel cover and the clutch. Only a thin washer and nut on the outer side of the bearing on the belt cover
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Make sure the cover is completely on the bike, use a couple of the middle bolts to hold it in place, then put on the clutch nut and washer.
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I just realized I am missing item #9 on the assembly drawing. Wonder if that would do it
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No, but not having it will destroy your variator in short order.
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Sometimes that washer becomes stuck to the outer variator half.
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Maybe a video of a disassembly and reassembly of the transmission will help you find your error. Starts at the 12 minute mark.

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[quote="CrackedEgg"]
Maybe a video of a disassembly and reassembly of the transmission will help you find your error. Starts at the 12 minute mark.

Thanks for the post
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GTS4life wrote:
{
Maybe a video of a disassembly and reassembly of the transmission will help you find your error. Starts at the 12 minute mark.

Thanks for the post
Hope it helps. The rear tire looks brand new. Did you take the wheel off just before doing the transmission? Was it reinstalled correctly?
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I agree with those above. confirm that the front variator plate has'nt pinched the belt stuck. Then reset the belt inside the clutch to be as deep as possible. just squeeze the clutch with both hands, it will fall into the groove further. is it possible to post a short video of what its doing ?
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My bet is the variator is pinching the belt sin e I have not placed the belt deeper in the clutch. Once I get the thin washer in between the two variator disc I will post a video before clutch nut install and after.
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So I received the washer that goes between the variator halves and installed it. That was NOT the issue. It turns out the washer I used for the clutch nut was larger than the OEM recommended and was clamping on the bearing when torqued. Used the right washer and am back to riding. Thanks to everyone who gave me some great tips and helped me troubleshoot this.
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GTS4life wrote:
So I received the washer that goes between the variator halves and installed it. That was NOT the issue. It turns out the washer I used for the clutch nut was larger than the OEM recommended and was clamping on the bearing when torqued. Used the right washer and am back to riding. Thanks to everyone who gave me some great tips and helped me troubleshoot this.
Thanks for posting the resolution to this problem.

Assuming it all ran before this work, I'm really confused how you came to have a "too thick" washer there. I might have missed it, but I don't think you said you replaced the clutch itself? So where did this bad washer come from?
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Glad you sorted it and I'm impressed you made the effort to do it yourself.

Threads like this make me glad I pay my mechanic $500 to do the job. It would drive me bonkers otherwise, although I like to troubleshoot A/V issues so each to their own 🙃
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