New Belt and Variator Tool.

Just got around to installing my new belt. Got the oem one from Honda. Payed $197CDN at the dealer, took 3 days to get after I ordered. The old one was the original 2005 with 24000 klm's.

Old belt outside: 26.4mm
New belt outside: 26.4mm

Old belt inside: 19mm
New belt inside: 20mm

The old belt was not deteriorated in any way, no cracking when I folded it inside out etc. Bike was always stored inside. The old belt has got plenty of life left in it yet. At least now I have a good spare. Took me about a half hour to change. Here are some pics of the variator tool I made earlier on in the summer when I installed Dr. Pully sliders. Hopefully the measures will help someone make one because it cannot be done without it. The metal is 1/8"X1". Bolts are 1/4"X1".

Nice job, nice pictures,thank you I'll be making one soon as I want to do a belt change after riding season is over for a while.

thank you

Great job and photos hotwings! I made one like that, from info on this site, when I changed my belt and installed Dr. Sliders in my 08 SWing. I should have "measured twice" tho because the long arm was about 1/8" to 1/4" short. I just put a piece of metal under the arm and it worked fine. I made it from some scrap laying around so I'm not out anything but did learn how to read a tape measure.

I made my variator tool as per hotwings' example and it works beautifully

I will also be making one of those very soon and especially appreciate that the author has used a tape measure which shows both metric and imperial measurements. Thank you very much!

:not worthy: Thank you Hotwings for a very informative post. I also clicked on the thanks icon.

With the interest in a variator removal tool, this is a very good description of a tool Hotwings made.

Pretty much like the one I made out of shop scraps. The measurements aren't critical, as long as one or both of the bars are 18" or longer. Too short and you can jack the bike off the stand getting the nut loose. The closer fit you can find for the bolts going into the variator will work best and damage or scratch the variator less than thinner bolts. To make a smooth fit I used two bolts on the ends of the bars backwards. Choose two bolts that have shanks long enough and of a diameter that fit into the variator hole snugly. Cut off the head of the bolts, smooth the cut off end with a bit of radius using a file or grinder and attach the bolts to the strap ends with a nut on each side. Works great, gives a very nice solid fit.

exdavd. thanks.

I guess a picture isn't worth a thousand words!

Nah, just some details. We all do it a bit differently and most all get it done.

I made my variator tool with a 3/16" x 1 1/2 "x 18", that one end serves as tire removal bar .2 tools in one. You can also make one from a 1/2" x 4" by 18" long plywood, drill a 1" hole to place over the variator nut ,and 2  ,1/4 " x 1 1/2" bolts to hold the variator .

Yes indeed, there's a lot of ways to skin this cat!

How far away are those 2 bolts on the tool that go into the variator?

I don't remember but if you make the arm on the tool so that the short arm is free to swing it doesn't much matter, just adjust it to fit.