Hyosung GV650 / ST7- Front Drive Pulley Removal without Belt / Chain Tutorial

[Chopper_Whitewolf]

 

I can’t be the first to face this issue but have seen very little in the way of advice online.
Drive belt was dry rot and snapped while riding. Replacement belt for a 2008 GV650 is 300 quid and only made by one manufacturer. Decided to do a chain conversion courtesy of the X-Ring Conversion Kit running a bog-standard 520 O-ring chain. This future proofs maintenance down the road (Pun intended) as I can pick up 520 chain at any bike shop. The trouble was finding a way to immobilise the front drive pulley in order to break the retaining nut loose.

Conventional wisdom says to put the gearbox in neutral, stand on the rear brake pedal, lean over the seat and with a breaker bar and bust the drive pulley/sprocket nut loose. However, that only works if there is a belt/chain attached. My drive belt was dry rot from sitting in a tin shed for 4 years prior to me purchasing the bike and snapped in two places.
After far too many swear words, in desperation, we pulled out a bit of rope and lashed it round. Should have done this first off. It worked a treat.

There are certainly a plethora of ways to get this done, but this was by far the quickest and easiest method we found.

Hopefully this finds its way to someone else in similar circumstances.

--==I have come to comfort the disturbed and to disturb the comfortable==--

[♠️ MARCEL]

Never seen the ropes being used that way lol, great write up!

// Meditation doesn't mean you have to sit still....

[Chopper_Whitewolf]

Redneck engineering at it’s finest!
This is what happens when an East Texas cowboy and a Highlander wrench on a bike in a Glasgow car park.

--==I have come to comfort the disturbed and to disturb the comfortable==--

[Steve]

Just be careful with the drive pulley / belt when re-assembled. At my last MOT the garage found what I feared to be a clutch rattle was in fact the pulley coming loose and making a freedom bid! Not something I’d kept an eye on during (basic) maintenance.

[Chopper_Whitewolf]

Thanks for the heads-up. Though I’m afraid I may have the opposite problem as I over torqued the front drive sprocket nut but will definitely be keeping an eye on the entire assembly. The X-chain conversion fitted perfectly without any fuss, but I’m still a tad nervous about either of the sprockets coming loose. Not really a fan of chain drive but it is the best option for a GV650 as old as mine. Definitely will go through every last nut and bolt before getting a Stage 1 ECU tune

--==I have come to comfort the disturbed and to disturb the comfortable==--

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