ray marine st4000+ belt tension the real fix

[Moltensurf]

problem soled.....for real
I have the older black version. I had the tensioner loosened all the way, but the belt was still to tight.
I bought the d169 at5/750mm belt from poly belt. I thought I bought the wrong belt; I called ray marine, this is the belt they recommend. I tried all the tricks I could find on the forum; none of them worked.
There are two pieces to the hub. The part with the motor attached, and the other. on the other piece where the belt grabs when unit is engaged, I took some 40 grit sand paper: and sanded around it. I'd sand a bit then snap it together to test it. it wasn't a whole lot I had to sand. when I finally sanded enough so the hub would slide easily while disengaged, I used 60,100,120,220 to smooth the plastic back out. It works like a charm now. If the belt stretches over time there wont be any problem because there is room for full adjustment, because I had the tensioner in it's loosest position.
The tensioner is located behind a little plug next to the motor, on the opposite side of the lever. I removed it by using a sharp pointy object, I had to stick in the plug then pull it out.
good luck and happy sailing. :thumb