I got around to working on my belt slip issues today.
I removed and soaked the belt in degreaser and disassembled everything leading to a few discoveries.
The front sprocket was loose. The bolt hadn't completely back out yet, but the sprocket was moving around. The sprocket cover was clearly keeping it in there:
You can also see where the movement has worn away at the top cap:
My bearing seals have fallen apart/out. For now I've just jammed them back in and used an extra bit of rubber as a gasket over the top. Does anyone know how to reseat these seals...can I buy new ones...does it even matter, or do I need a whole new bearing?
After I cleaned up the belt and tighten down the top cover again I was hopeful that my belt slip issues might be solved, but nope...still just as bad.
So I took the belt off again, and compared it my other unused belt:
New is on the left, old on the right.
It's a bit hard to see, but there is a noticeable amount of wear on my old belt...enough to make it slip I guess.
Changing to the new belt has solve it...no more slipping.
I reduced my mode 3 to 166 phase amps now as I don't want this happening again. That being said, my belt wore out really fast...I wonder if it was also caused by other factors like the lube I added to quieten it down, or the front sprocket moving about.
Adam also sent me a STL to 3D print a 15T (13T chain equivalent) front sprocket. Thanks Adam!
I test fit it to see if it would fit under the sprocket guard and pleased to say it does:
I think a 16T might even fit also, but then it might be too slow and cause tension problems.
So I will probably get one of the 15T ordered also as I think it might make my worn out belt work again.
I only put about 500km on the first belt.
Lets see how long the second belt lasts with lower power!
Cheers