Originally posted by Adoika
This may sound stupid but are you sure that the pulleys are numbered correctly? ie 18t on inside and 2 19t on the main shaft? Have you tried reinstalling the original plastic pulley? Mine keep popping the front belt off until I realised that the belt and pulley were knackered.
Dazza this is the answer you may have been looking for!! as sway bars or foam tyres can not make a pulley pop out.