Fitting Underdrive Pulley to Cayman S

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Chris_in_the_UK
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Chris_in_the_UK PCGB Member
2014/05/11 20:45:12 (permalink)

Fitting Underdrive Pulley to Cayman S

Hi folks - finally got down to fitting the RSS Underdrive Pulley I bought during my recent US road trip and visit to Sharkwerks.

For those who are not familiar with this modification it is a pretty cost effective way of releasing some horsepower and torque.

Here is the Planet9 version of what I did but using a different pulley to the RSS one I used.

http://www.planet-9.com/reviews/cayman-performance-modifications/p160-mantis-sport-underdrive-pulley.html

1. This pulley's and belays are accessed from behind the seats - just pull them as far forward as they will go and tilt them towards the windscreen.

2. Remove the luggage bar - this has a couple of torx screws so you need the relevant bit - then pop out the retaining stud and carefully remove the carpet and sound insulation combo.

3. There are several bolts and a couple of nuts that need removing from the aluminium access panel which can then be removed - the edges of the panel are very sharp as this is a pressed item at manufacture - I smoothed these of before I replaced this.

4. Once tha access panel has been removed then the pulley's and belts are visible. Use a socket on the tensioner pulley to ease this off against it's spring and the belt can be removed.

5. RSS provide a 'stop' bolt for the pulley that is to be replaced (the bottom one) and you just need to used a socket wrench to rotate the engine to line up one of the holes in the pulley with the boss on the engine that has a locking hole in it. Once you have done this the centre bolt can be undone - normal thread orientation, just a bit tight.

6. Once the pulley is off, you need to cut approx 5-6mm off the locking boss so the smaller under drive pulley does not foul it - despite how it sounds, it's no big deal (honest). I found it easier to remove the nearest idler pulley to give easier access (visible by the vacant boss in the last picture).

Here is a comparison of the pulley sizes - black one is the RSS under drive pulley.



RSS state that the standard drive belt is ok to use with their pulley, but the chaps at Sharkwerks recommended a slightly shorter belt which I grabbed at the same time I picked up the pulley.



And a final (cr@p) picture of the pulley in place.



As regards how it drives........

Not had time yet! All runs ok so looking forward to seeing how this feels - ran out of time doing the engine mount work (see my other post).

Rgds.
Chris

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    Re: Fitting Underdrive Pulley to Cayman S 2016/05/02 21:58:58 (permalink)
    Can you recall the type of bolt supplied to affix through the old pulley into the block - M6, M8? I am just about to embark on this task ;-)
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