General

WARNING

Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over bending can damage belt resulting in premature failure, which could cause loss of control and death or serious injury. (00339a)

In the case of stone damage to belt, inspect the sprockets for damage and replace as required. If replacing belt, always replace all sprockets: rear (1), idler (2) and transmission (3). See Figure 1.

Cleaning

Keep dirt, grease, oil, and debris off the drive belt, sprockets and belt tensioner. Clean the belt with a rag slightly dampened with a light cleaning agent.

Sprockets

1.	See Figure 2. Inspect each sprocket tooth (1) for: a. Major tooth damage b. Gouges caused by hard objects
2.	Replace sprockets if major tooth damage exists.

1	Rear sprocket
2	Idler sprocket
3	Transmission sprocket
4	Tensioner

Figure 1. Sprockets and Tensioner

1	Tooth
2	Groove

Figure 2. Rear Sprocket

Tensioner

1.	NOTE Wear through anodized coating is acceptable. The part is aluminum and will wear. See Figure 1. Inspect surface of tensioner pulley (4) for: a. Excessive wear on pulley face b. No large knicks, gouges or grooves c. Confirm the bearing spins freely
2.	If belt adjustment is needed: Clean behind tensioner. a. Loosen tensioner screw. See Electric Vehicle Powertrain (EVPT) → TENSIONER PULLEY AND IDLER SPROCKET. b. Move tensioner away from idler bracket. Do not take off. c. Clean between tensioner and idler bracket. d. Install tensioner. e. Adjust belt deflection.

Drive Belt

See Figure 3 and Table 1. Inspect drive belt for:

Cuts or unusual wear patterns
Outside bevel wear (8). Some beveling is common, but it indicates that sprockets are misaligned
Outside ribbed surface for signs of stone damage (7). If cracks or other damage exists near edge of belt, replace belt immediately. Damage to center of belt eventually requires belt replacement. However, when cracks extend to edge of belt, failure is imminent
Inside (toothed portion) of belt for exposed tensile cords (normally covered by nylon layer and polyethylene layer). Replace belt and transmission sprocket
Signs of puncture or cracking at the base of the belt teeth. Replace belt if either condition exists
Replace belt if conditions 2, 3, 6 or 7 (on edge of belt) exist

NOTE

Condition 1 may develop into 2 or 3 over time. Condition 1 is not grounds for replacing the belt, but it should be watched closely before condition 2 develops which will require belt replacement.

Figure 3. Drive Belt Wear Patterns

Table 1.

NO.	CONDITION	REQUIRED ACTION
1	Internal tooth cracks (hairline)	OK to run, but monitor condition.
2	External tooth cracks	Replace belt.
3	Missing teeth	Replace belt.
4	Chipping (not serious)	OK to run, but monitor condition.
5	Fuzzy edge cord	OK to run, but monitor condition.
6	Hook wear	Replace belt and sprocket.
7	Stone damage	Replace belt if damage is on the edge.
8	Bevel wear (outboard edge only)	OK to run, but monitor condition.