Mad Hornets CVT Belt Failure @ 4k

Beema41

New member
Hi all,

Some might remember that when I purchased my C650GT last year I went through everything on the scooter and gave it a huge service including replacing the CVT belt.

I ended up fitting a Mad Hornets Kevlar Belt as it is heavy duty and because I was fitting some Dr Pulley sliders I thought I'd beef up the drive train.

The bike has been going very well and is really enjoyable to ride.

Well yesterday my scooter is riding along when it loses power, the ACS system kicked in and the ACS light came on. There was a knocking sound from the CVT. I babied the bike home and immediately set to work removing the CVT to see what had gone wrong.

To my surprise I could smell rubber and started to suspect something sinister had gone wrong. As I removed the final cover bits of rubber fell out. I looked at the belt and noticed it appeared to be ok as it wasn't broken. Closer inspection by rotating the drive revealed several rubber teeth missing and multiple cracks.

So now I'm going to overhaul the entire clutch and CVT again. This time fitting a Dr Pulley HIT clutch and a Mitsuboshi Kevlar Belt.

In the process of removing the clutch I created a device for dismantling the spring system. The nut being 60mm required my purchase of a socket, which I expect I'll only use for this job. For the remainder I used 100mm x 100mm box steel and cut out an access port to get to the nut. I bolted it to my workbench. It worked first go!

I've taken a few photos and tried to upload them twice but they still appear too large.
 

RollaCosta

Member
Never heard of Mad Hornets, the following companies are Japanese - BANDO, MITSUBOSHI.
Italian Malossi is also a reputable maker, their product is sold via malossistore.com
 

wspollack

Active member
...
I've taken a few photos and tried to upload them twice but they still appear too large.
I've posted a lot of pics here, and the max photo size for this forum appears to be very small, right around 1MB. If you don't happen to be able to resize your pics, we can talk you through it (depending on operating system, etc.) or find another way (e.g., email them to me, and I'll do it).
 

Beema41

New member
I've posted a lot of pics here, and the max photo size for this forum appears to be very small, right around 1MB. If you don't happen to be able to resize your pics, we can talk you through it (depending on operating system, etc.) or find another way (e.g., email them to me, and I'll do it).
Hi mate, I'm not very technical when it comes to computers. I'm about 30 years too late. If someone wants to see the special tool I made I'll PM the image to them. Cheers Greg
 

Ceesie76

Active member
This is the set I am looking to get when it's time for me to fit a new belt / service the CVT system. I will stick to the Mitsuboshi brand belt:

 
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