pictures on how to replace primary belt on shovelhead

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Lilac LS-18 Motorcycle Maintenance Standards

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Filed Under (Lilac) by admin on 25-11-2010

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CYLINDER AND CYLINDER HEAD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Cylinder Bore 54 -0.01 54.1 Boring After boring honing should be performed Ovality 0.01 0.05 Boring After boring honing should be performed Taper 0.01 0.05 Boring After boring honing should be performed Oversize 0.25 steps 55 max. Do R and L cylinders at same time / 4 steps Valve Seat Width 0.8 – 1.0 1.3 Adjust Use a cutter Angle 45∞ Combustion Chamber Volume 18.2cc -0.5cc Remove carbon if heavy accumulation Compression Ratio 7.8:1 Head Gasket Thickness 1.0 Cylinder Head Nut Torque 3.0 kg/m (22 ft.-lb.) Out standard Adjust 8mm nut Intake and Exhaust Ports Port Wall SurfaceMust be smooth Remove carbon Intake and Exh. Valve GuidesOD 12 +0.09 +0.1 ID 7 +0.01 -0.0 7.06 Exchange Intake Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Exhaust Valve Stem Diameter 7 -0.02 -0.03 6.9 Exchange Head Thickness 1 0.7 Exchange Intake and Exhaust Valve Seat Face Width Range 0.8~1.0 1.3 Use valve seat cutter Intake Valve Guide Clearance 0.02~0.04 0.08 Replace valve or guide Exhaust Valve Guide Clearance 0.06~0.08 0.12 Replace valve or guide Valve Spring (Large) Installed Load 10.2 kg 8.7 kg Replace Fitted length 31.5 Free Length 36.5 34.7 Replace Tilt 1.5/100 3/100 Replace Valve Spring (Small) Installed Load 5.48 kg 4.65 kg Replace Fitted length 29.5 Page 4 of 10 Free Length 33.5 31.8 Replace Tilt 1.5/100 3/100 Replace Rocker Arm ID 12 +0.00 +0.02112.07 Replace Rocker Shaft OD 12 -0.06 -0.024 11.92 Replace Arm and Shaft Clearance 0.045~0.006 0.10 Replace arm or shaft Tappet Clearance 0.05 Out standard Adjust Measure cold at TDC Rocker Arm Ball Surface 1.8îR -0.006 -0.024 Replace if severe wear Pushrod Bend 0.1 0.5 Straighten Over 100mm (2) CRANKSHAFT, PISTON AND CONROD MAINTENANCE ITEM STANDARD REPAIR LIMIT METHOD REMARKS Piston OD @ Top 53.65 -0.02 Max Diameter 53.95 -0.015 53.85 Replace Ovality 0.1 Piston and Cylinder Clearance 0.04~0.05 0.15 Replace Piston Ring Groove Clearance 0.03~0.07 0.10 Replace Piston Oversize Step 0.25 4 steps Top Ring and 2nd Ring Thickness 2 -0.01 -0.03 1.92 Replace Width 2.5 -0.01 0.55kg Tension 0.85 – 1.15kg 1 Replace End Gap 0.15 – 0.35 Replace Oil Ring Thickness 3.2 -0.01 -0.03 3.12 Replace Width 2.5 -0.1 Tension 1.0~1.3kg 0.65kg Replace End Gap 0.15~0.35 1 Replace Ring Gap Position 120∞ 3 equal spacesOut standard Adjust Avoid Piston Pin Axis Ring Oversizes 0.25 steps 4 steps Piston Pin OD 15 -0.0 +0.006 14.95 Replace Pin Hole in Piston ID 15 +0.012 -0.015.05 Replace Pin and Piston Clearance -0.006 ~ +0.012 0.06 Replace Hand push fit piston at 100∞C Conrod Small End Bush ID 15+0.027+0.016 15.07 Replace bush Conrod and Piston Pin Clearance 0.01~0.027 0.07 Replace Crankpin OD 24.94 +0.0+0.0124.90 Replace Crankpin Roller OD 5 (+0.001+0.003) Refer to conrod ID Replace 3Sizes; 52 per assembly for selective fit 5 (+0.0 -0.002) 5 (-0.003 -0.005) Conrod ID 34.95+0.03+0.02435.02 Axial Play 0.2~0.4 0.5 Adjust Radial Play 0.026~0.036 0.06 Replace

Harley-Davidson EMERGENCY DRIVE BELT REPLACEMENT KIT Installation Manual

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Filed Under (Harley Davidson) by admin on 24-10-2010

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1. Shift transmission to neutral. Before installation of the emergency belt, to avoid personal injury and/or vehicle damage, secure the motorcycle. Both stand and motorcycle must be on solid, level ground. Failure to follow instructions could result in death or serious injury. 2. See Figure 1. Remove spring clip (4) (if present) and loosen rear axle nut (1). 3. Loosen rear axle adjuster (3) (or adjuster nut, if so equipped) on each side of motorcycle, and move rear wheel to full forward position. 4. Remove the damaged/broken belt. 5. Inspect sprockets and belt guard (2) for damage and/or debris. Remove any debris. If sprockets and belt guard are not damaged, proceed with the installation. 6. Remove belt guard. 40171-97,40146-00 1 WARNING i06186 Figure 1. Axle 1. Axle nut 2. Belt guard 3. Adjuster 4. Spring clip 2 4 1 3 7. See Figure 2. Install feeder strip on emergency belt. 8. Feed strip around transmission sprocket in a counterclockwise direction over frame cross support. 9. See Figure 3. Interlock the “v” ends of the emergency belt. a. Insert a hex socket key in the fourth (4) and ninth (6) tooth holes. b. Place the splice block (2) over the seventh (5) tooth hole. c. Install a socket head set screw (3) in the seventh tooth. Tighten using another hex socket key. d. Move the block to the next tooth, and repeat installation steps (b) and (c) in each tooth until all 12 screws are installed. NOTE There are 16 screws included in this kit. However, only 12 screws will actually be installed in the belt. The remaining four screws are spares. 10. See Figure 4. Grasp the emergency belt at the mid point of the lower run between your thumb and forefinger and lift the belt up to take up any slack in the belt. Measure the distance that the belt deflects (2) under tension (1). When two pounds of tension is applied to the lower run of the emergency belt, the belt deflection should be within the following measurements

BMW R850, R1100, R1150, R1200 Oilhead Maintenance Manual

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Filed Under (BMW) by admin on 16-11-2010

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cold Engine and Drivetrain Procedures Check Alternator Belt Tools Parts T-handle hex – 4mm none Note: In most cases the alternator belt does not need to be checked any more. Early models should have the pulley and belt upgrade that came out a few years ago. Current recommendations are that the belt is installed and adjusted, then not disturbed until 36K when replacement is specified. 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Check the belt for cracks or shredding. 4. Check the belt tension, quite tight, ~1/4″ deflection when you press on the center. Note: Paul Glaves suggests that proper belt tension is when you can twist the belt ~90 degrees, midway between the pulleys. If you can twist it more than 90 degrees, it is too loose. If you cannot twist it 90 degrees, then it is too tight. 5. Leave the cover off for the valve adjustment procedure on the next page. Change Alternator Belt Tools Parts T-handle hex – 4mm alternator belt socket – 13mm ratchet wrench – 13mm torque wrench 1. Remove the four bolts holding the black plastic alternator belt cover at the front of the engine, 4mm T-handle hex. 2. Remove the cover by sliding it straight down. 3. Loosen the 2 nuts and 1 bolt, 13mm, that hold the alternator – one is on top and one is on each side, thus allowing the alternator to pivot down. 4. Remove the old belt. (Some bikes have a pipe that traps the belt – loosen it enough to get the old belt out and the new belt in) 5. Install the new belt being sure it is properly seated. 6. BMW calls for a tensioning torque of 5.9 ft.lb. (8 Nm) on the adjuster bolt on the left side of the bike. You have to get at this bolt from the alternator side and you may have to lift the tank. Alternatively, you can pry the alternator up with a large screwdriver to tension the belt. 7. Once the belt is under proper tension, tighten the 2 nuts and 1 bolt, 13mm, to 15 ft.lb. (20 Nm). 8. Check the belt for proper tension (see above) and proper seating alignment

Harley-Davidson BIG-TWIN 8mm BELT DRIVES (OPEN OR CLOSED) INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 16-04-2012

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INSTALLATION : The spacer behind the front pulley should be removed prior to installing the belt drive. This spacer may or may not be required to correctly align the pulleys. If a spacer is needed for alignment, various sizes are available from your local Primo Belt Drives dealer (part number PX-1 =package of 6 various sizes). With all supporting components installed, install front pulley, lubricate and reinstall the clutch hub. Loop the belt around the front and rear pulleys, and gently push into place. Use the washer and nut supplied with the kit on the front motor shaft, (always use an impact wrench on splined shaft motors) tighten to 80-100 foot pounds of torque. After installing and adjusting clutch, track the belt by turning the pulleys. If needed us a straight edge between the front and rear pulleys to check alignment. Improper alignment of the pulleys will result in reduced belt life. Spacing the motor pulley outward will cause the belt to track towards the outer primary cover. If spaced too far out the belt will rub on the inside of the clutch shell. ENCLOSED INSTALLATIONS: The same disassembly is required, with the exception of the clutch hub and inner primary. We recommend using our PC-1000-Acomplete clutch assembly. Loop the belt around both pulleys to insure that you have the proper belt for your pulleys, then gently push the unit into place. Use the washer and nut supplied with the kit on the motor shaft. Torque the motor nut to 80-100 foot pounds . Adjust the clutch & check belt / pulley alignment. Before installing the primary cover be sure that everything inside clears both the outer and inner covers. In some cases a small amount of metal may need to be removed from one or more of the bosses on the inner or outer primary covers

1937-1984 Big Twins BRUTE II EXTREME BELT DRIVES INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 27-10-2010

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Remove the outer primary cover. Remove the front pulley, chain, compensator & chain adjuster Remove oil lines to primary and plug or clamp to prevent leakage. Cut the chain oiler hose 3 inches from the oil pump and permanently plug. All belts must be run dry without lubrication of any kind. Therefore, remove all oil from inside the primary covers. The spacer behind the front pulley should be removed prior to installing the belt drive. This spacer may or may not be required to correctly align the pulleys. If a spacer is needed for alignment, various sizes are available from your local Primo Belt Drives dealer (part number PX-1 =package of 6 various sizes). Install the front pulley supplied in the kit. Loop the belt around both pulleys to insure that you have the proper belt for your pulleys, then gently push the unit into place. Use the supplied washer & nut on the motor shaft. Torque the motor nut to 80-100 foot pounds. If installing a PC-1000-Aremove the clutch hub & clutch basket. On tapered shaft models check the fit on the shaft & the fit of the keyway in the hub. Install the key in the mainshaft, making sure it is firmly seated (use of super glue or threadlock in the keyway is helpful to keep the key from sliding out of the keyway during clutch installation). Tighten the clutch hub nut(left-hand thread) to 60-90 foot pounds. 1 After installing and adjusting clutch, track the belt by turning the pulleys. If needed use a straight edge between the front and rear pulleys to check alignment. Improper alignment of the pulleys will result in reduced belt life. Spacing the motor pulley outward will cause the belt to track towards the outer primary cover. If spaced too far out the belt will rub on the inside of the clutch shell. Before installing the primary cover be sure that everything inside clears both the outer and inner covers. In some cases a small amount of metal may need to be removed from one or more of the bosses on the inner or outer primary cover.