Constant problem with outer pulley on FXR180

I bought a second hand FXR180 that had had a "catastrophic event" in the transmission - I thought that most likely the variator nut had come loose and could be easily fixed. It was quite a mess. Actually had cracked the transmission case.
After replacing the case and fitting everything back as it should (including thick and thin washers in the correct order and making sure belt was not caught) and torquing the nut to 75nm with loctite I am now finding that the bike keeps shredding the inner splines of the outer pulley. I've gone through 3 in about 2 months. The nut is not coming loose - still rock solid each time. Can't work out why this keeps happening and have pretty much retired the bike due to this. The crank splines still look ok and the bike rides ok until the pulley strips out. Any ideas what could be causing this or how to fix it?​

 

Are you fitting the small washer that sit's under the variator nut?

 

Thanks. Yes I am fitting that thin washer. It has taken the shape of the variator nut quite a bit. The inside is mushroomed a bit but it is not split or anything.

 

I would fit another variator complete including centre spacer tube and all the washers, new nut.

 

I will try that thank you. Do they come with everything apart from the nut?

My bike is standard at the mo but plan on doing carb, reed block, head, clutch springs and that's about all. Would you go Malossi or PM tuning variator? Heard that Polini can wear quite quickly.
Thanks.

 

The std 180 variator work's fine, as you may know it is different to a 125 so personally I'd keep the 180 set up.

 

You know where I can get one?? I have been looking hard on the net and all I can find is a "standard variator" from beedspeed but I emailed them and they told me it was not genuine but made by Italian company RMS. It is quite a bit cheaper than the aftermarket ones but concerned that quality may not be as good.

 

gilera spares do them i think, as do scooter centre in germany

however if its stripping them out id imagine the crank splines are pretty worn. a bit like fitting a new chain to old sprockets, the teeth on the sprockets will slip and kill the chain quickly

 

What do you reckon?

 

wouldnt have a clue, but to strip pulleys either means your buying used worn pulleys or the cranks worn and is quickly slipping inside the pulleys themselfs