How difficult is it to replace the belt on the GV??
Mines an 06.
Pretty easy as *most* scooters are all the same EXCEPT that there are a few small but important differences with the GV's belt system.
Basic steps (it's been a couple of years)
1. Place scooter on the center stand and place the kickstand / side stand up and remove
(1) 8mm bolt about 12 inches from the front of the kick stand. Slide the plastic piece back about 1/2" and remove it from the rear.
2. Remove
(4) small chrome bolts (10mm) that hold the plastic cover on - be careful not to loose the washers AND rubber grommets.
3. remove (6) 8mm bolts then pry in the hole on the bottom / center with a small pry bar to un-stick the metal.
4. Place a pry bar in the center of the REAR pulley and pry against the spring about 3/4" until it "unlocks" and relieves the tension on the pulley.
(*)
WARNING failure to follow step #4 caused my front pulley splines to get stripped when reinstalling the belt!
5. There are
two large 19mm nuts. The rear does
NOT require removal but it is a good idea to remove it to inspect the rear clutch assembly. Remove them (ideally) with and an impact / compressed tool aka air gun OR buy or make a holder tool (remember that the front and rear require different fittings for the pulley holder). If doing by hand use a 1/2 breaker bar or 1/2" ratchet AND a ~ 20" (1" ID metal pipe to increase force - available at Lowes, Home Depot or any place that sells pipes ~ $4) striking the tool helps to generate impact / shock to bread things free. You will also need a short ~ 1" socket extension - available at any auto store $4.
6. Separate the front pulley. Only need to remove the 19mm nut, the washer under it and the outer pulley facing you. Lube the spline with a
tiny bit of grease or anti-seize (get a tube at any auto store for $5).
7.
OPTIONAL - remove the nut on the rear pulley and carefully remove the parts noting or taking pictures of the order and blow out dust and inspect clutch assembly for wear. Mine are original and still in good shape at 16K miles.
8. reinstall rear pulley and nut then new belt (noting direction - many but not all belts can rotate in either direction).
9. Reinstall front outer half of pulley and be sure it slides on spline correctly and bottoms out - if belt does not have plenty of slack pry the rear pulley apart again and it should stay separated "unlocked" to allow the font pulley to go on easily. Now put the washer on, tighten the nut by hand. Tighten front nut with a quick shot with the impact wrench OR ideally use the holding tool and a torque wrench. Repeat for rear pulley. Do NOT apply thread locker to threads.
DO NOT OVER-TIGHTEN.
10. Do NOT install the covers - take a test ride.
11. Reinspect and reinstall the metal cover count to (6) as you tighten each bolt - DO NOT OVER-TIGHTEN. Reinstall the plastic cover (4) 10mm bolts (watch-out I lost a grommet - you do apply thread locker and only hand tighten that bolt to avoid damaging the plastic. Apply medium thread locker to ALL 4 chrome bolts or they will loosen up constantly and probably fall out.
12. Retest and save your old belt and any used parts then dispose of after 30 days OR keep your old belt as a spare if you take road trips.
Kymco Grandvista / Grand Dink Belt Change:
