Changing the drive belt on a Honda scooter is not an overly complicated process that requires a lot of mechanical know-how, but it is a relatively involved process requiring you to remove, disassemble, replace, reassemble and reattach multiple components of your scooter. Fortunately, changing the Honda scooter's drive belt is not a process that needs to be performed often. Unfortunately, changing the Honda scooter's drive belt can be painstaking when it does need to be performed.
Unscrew the two bolts holding the black plastic intake to the top of the variator case. Both the intake and variator case are located on the left side of the scooter.
Unscrew the single bolt securing the intake case underneath the rear tire well.
Pull the intake case out and off the scooter. This will give you access to the bolts holding on the cover to the variator case in which the drive belt is located.
Pull the kickstart's pin and remove the kickstart from the outside of the variator case. You will need to loosen the bolt head of the pin with a socket wrench before pulling it.
Remove the cover of the variator case by unscrewing the six perimeter bolts holding the cover in place.
Disengage each pulley wheel in the case from the variator system. Unscrew the bolts holding the wheels in place through their centre points. Use an air-powered impact wrench to unscrew these bolts.
Pull the old drive belt off of the back and front pulley rods in the variator system.
Loop the replacement belt over the back and front pulley rods in the variator system.
Re-engage each pulley wheel in the variator system. Be sure to replace the spacing washers on each rod, as well as the coupling part on the front pulley wheel.
Cover and attach the variator case with the case lid.
Reattach the kickstart.
Reattach the intake case.
Keep track of the spacing washers directly behind each pulley wheel, as well as the coupling part that marries the kickstart to the variator system.