The Yamaha Road Star Warrior Forum

 In preparation for last years Warrior Fest, I installed a new Shinko 005 meat out back, Second ride on the new tire, my stock belt, with 10k miles on it gave up. Installed a gates belt that several other members here were using, Two weeks after the trip broke the belt again. Replaced it this time with a Panther belt. This one lasted maybe a thousand miles. didn't break but pulled 10 teeth out the middle. With me so far? This time I step it up to a 1.5 wide gates belt, With a 1.5 wide x 70 t pulley from a RoadStar, told this was "Bullet Pruff" Put this set up on the road Aug. 07, put 2k on it, Broke the wide belt this past weekend.

 The three that broke, all the same way, power shifting into second gear., I checked several Warriors at the Dragon last year, for the belt tension, I'm sure of my pulleys / belt line up. I do set up the belt tension with weight on the bike.

 And yes I've exhausted the search function looking for help.

 wow. That’s a lot of belts. This may be a stupid question but I have to ask; did you correctly adjust the belt tension? Too much tension would result in the type of premature failures you are experiencing.

EDIT: 

 Nevermind. You updated your post with the tension info. Since you have also checked alignment I'm out of further ideas. 

What is your belt tension at? Any mods to the rear suspension or wide tire kit?  If you belt gets to tight and the suspension moves or you give it some throttle or both the belt can snap.  If it gets too loose the same thing can happen cause the slack can "wind up" and the sudden tension can snap them or the pulley can ratchet around the belt and tear out teeth.  A miss aligned belt can cause excess friction and cause the belt to get hot and snap.  I cant recall the exact spec for belt tension but I will post it tommarow when i get there, im a tech at a yamaha suzuki dealer and the only reason we see broken belts is due to the above conditions. I have 6k on my stock belt wih minor motor mods and in no way do i ride my bike nice and have never had a belt issue yet (my luck next time I ride my bike I'll snap a belt...)  we see bikes come in with over 25k on their bikes still on stock belt.  Let us know what is done to the suspension and how your were riding it when the belt snapped (be honest, we all love burn outs  ) and maybe we can give you a better idea on what is happening.

Yes checked the tension carefully, When the first belt broke, that was the fourth rear tire change, with no belt issues, I didn't think it was to tight.

damn dude thats alot of belts broken in a short amount of time. what kind of mods have you done to the old girl? i would also check your pulleys very closely for some type of damage that maybe causing this, thats just a lot of belts to break something is got to be outta wack somewhere

Just for your info the Panther belts are a wost choice for belts....They have been known to do just as you said it did in just a few hundred miles.  Also the wider belt is actually not as strong as the stock narrower belt.  If you are having these issues it is probably from running that drag tire on the back.  Somethings got to give and if the tire is not slipping then the belt may brake.  Being an aluminum frame on the Warrior it does have some flew in it.  That is why my Drag bike has frame supports built into it, other wise the chain I am running would become very loose on launch off the light.  the smae thing will happen with the stock bike and the belt and it is like a rubber band it snaps back after launching hard and SNAP!! there goes another belt.  Go with chain drive if you are having so many belt problems.

How many teeth and what Mfg's front pulley are you using before and after the failures. A smaller frt pulley (32T stock) puts more stress on the belt and that's a fact    Edited: Your gallery photos show a Baron pulley (teeth?)

I would agree that the Dayco Panther belt is a very poor quality rubber belt and a piece of $hit that is not suited for the Warrior.

The GATES-HTD Poly Chain Kevlar belt : 42616 sold by Phats: BDL-PC-130 is being used by 2-members of the site very sucessfully under harsh drag racing conditions w/o failures on modified HP engines. Based on their gallery specs they are both using the Road* 32T Billet Front Pulley

The correct belt tension for the warrior .24 - .31 inches @ 10 pounds of force applied to the bottom of the belt upwards at the measurement spot or around halfway between the sprockets. This spec seems "Too Tight" for most people becasue the dont think that belts have stretch.  Like I said before that if a belt is loose it will snap under harsh acceleration and can break.

uhhuh:

 The three that broke, all the same way, power shifting into second gear., I checked several Warriors at the Dragon last year, for the belt tension, I'm sure of my pulleys / belt line up. I do set up the belt tension with weight on the bike.

A guy walks in to his doctors office, says "doc, my ear kills me when I put my finger in it."  "Well don't do that." says the doc.

 Just messing with you.  That sucks.

Its 31T  aluminum piece, I've been running for  ~6k, I'm having the stock pulley machined to fit the wider belt.,

If you break another one, you may want to look into joining the chain gang. JMO. I know belts arent free and it kinda sucks waiting for help beside the road.

The stock OEM Warrior pulley is too narrow for the 1-1/2" belt. It's 1-3/8" between flanges

There are only 2 flavors available in 32T for the Road* 1-1/2" belt. Barons & Yamaha 7075 aluminum!

As stated earlier, there are 2-members running with this combo as well as many others like me with the 33T w/o belt issues.

Good luck

 Sorry i left out that the belt should tension should be meausered with the spec given above with the bike on the kick stand, NOT WITH IT UPRIGHT OR WIH RIDER ON IT!!  If you do it other than on the kick stand the belt will be a little on the loose side. This spec is taken right out of the Yamaha Warrior service maunal at my shop. 

Alan,  you are correct, been awhile since I looked at the stock pulley. I was thinking that just cutting the inside flange would let the wide belt fit. duh!  Thanks for the help!