this is a re post of what i ran into when i changed mine:
for those of you that havent changed your drive belt yet heres what i ran into.
first of all you need to remove the air box. this is easy just loosen it from the carb (hose clamp) and the two mounting screws on the bottom of the air box attaching it to the belt cover. thats all you have to do to get the air box off then.....
remove the kick starter lever. to remove it you must remove the single bolt that holds it on completely, the shaft has a notch in it so if you just loosen the bolt it still wont come off, must remove the bolt and then it wiggles right off. then i suguest getting a box flap or some cardboard and make holes in it for the bolts that your going to remove in the shape of the cover so they dont get mixed up (there all diffrent legnths). after removing the bolts your ready to remove the cover, but first remove the 2 screws on the body by the passenger foot rest and the one under the body in the same place. this is to alow the cover to go over the variator and be removed.
i just loosened the body panel up some and with a few gentle taps on the belt cover with a rubber malot it pops loose then with a little pull you can get it past the body panel and remove it. it worked for me anyway. just be carefull not to pull to hard on the body panel so you dont brake it. now you can see the variator and cluch assembly.
to put the new belt on you have to remove the variator nut. i tried to remove it with a screwdriver stuck in the cooling fins to stop it from turning and my scocket but snap! off came a cooling fan blade ( DO NOT JAM ANYTHING IN THE FAN BLADES!) you need an impact wrench, air or electric to remove it. i tried to get it off with a borrowed air impact wrench but my old compressor wouldnt give me enough psi to do the trick, so i borrowed an elect impact wrench and finaly removed it. with a good compressor with 120-150 psi a regular air wrench would work fine im sure. ok now you can remove the variator side. be sure to hold the back half of the variator when you wiggle the outside half off or like me your in for a suprise, rollers and clips spilling out all over the ground.....after some trial and error i figured out how to put the rollers back into the back half of the variator and then holding the roller cover and the back half of the variator together place it back on the shaft, then put the sleve back in that stops the outside half from going to far. now place the new belt on the pulley in the rear and over the shaft and sleve on the front and put the outside of the variator back on with a little locktite to make sure the nut wont come loose then use the impact wrench you used to remove it with and set the nut back on. then just re install the cover and air box and the body screws and your done.
for me it took 2 hours (not counting the time waisted until i was told by fulltilt about the impact wrench)
all in all it was a easy job, just need a little common sence.
i have no special tools, just a normal tool box, and i did it laying on the ground in my gurage, and i have NO special abilities when it comes to fixing vehicles so if i can do it anyone can.
just rember the metal cooling fins on the variator are very eaisly broken so dont pry on them and your going to need the impact wrench or equivelant for that variator nut.
hope this help out
if i can help out just ask.
good luck with yours!
