How to remove and change the variator, belt and rollers on a GP 800 and SRV 850?

After removing all the fairings to gain access to the variator cover, unscrew all the fixing screws of the small air filter.

In order to free the variator cover, the torque driver nut must first be loosened. To do this, lock the shaft in rotation using a 13mm wrench and loosen the nut with a 27mm wrench.

The cover can now be removed by unscrewing all the screws that hold it in place.

The variator nut can be loosened using a ratchet fitted with a 32 socket and the Easyboost wrench. If necessary, the handle of the wrench can be extended with a long tube to apply more torque.

The variator can now come out easily, along with the variator cap, the rollers and the hub.

Next, take out the torque driver-clutch-belt assembly. The belt comes off the torque driver easily.

Before loosening the clutch nut, mark a reference line with a felt pen so that it can be retightened to its original position. To easily remove the clutch nut, you will need to use the Easyboost tools. Start by loosening the clutch nut by 1/4 turn using the Easyboost holding wrench and the open-end wrench, striking a few sharp blows with a mallet.

Once the nut is unlocked, fit the torque spring removal tool following the instructions in the manual. This operation will release the clutch nut by applying slight pressure on the torque spring. Be careful, as the clutch is already at its stop, do not try to compress the spring any further.

The nut can now be removed by hand as the clutch is no longer applying pressure on it.

All that remains is to unscrew the shaft nut to gradually release the spring safely.

The spring is removed; it can now be replaced with a new and/or stiffer model to increase torque and pick-up.

For reassembly, repeat the operation in reverse order. Fit the tool back in place in order to compress the torque spring.

Once the spring is compressed, the clutch nut can be put back in place by hand.

Repeat the same procedure as for removal, fitting the torque driver holding tool. Using the open-end wrench, tighten the clutch nut until the previously drawn reference marks are aligned.

To make fitting the variator easier later on, the belt must first be slightly inserted into the torque driver. To do this, wooden wedges can be used to open it up.

Fit the torque driver, equipped with the belt, onto its shaft.

The variator nut must be retightened to a torque of 265 Nm +/- 13 Nm using the Easyboost holding wrench and a torque wrench fitted with a 32 socket.

After refitting the variator cover, the torque driver nut can be tightened to 170 Nm +/- 17 Nm.

All that remains is to screw back all the variator cover screws and refit the fairings.