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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

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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

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1999-2008 FLHT Series Harley- Davidson Trike Conversion Kit Installation Instructions

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Filed Under (Harley Davidson) by admin on 04-12-2010

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1. Place the motorcycle on the lift. 2. Place a suitable Jack under the Frame of the Motorcycle and tie down securely. 3. Remove Drain Plug from Primary Cover Assembly and drain oil. 4. Slide Rubber Boot off of the Clutch Cable Adjuster. Loosen and back the Jam nut away from the Clutch Cable Adjuster. Move Clutch Cable Adjuster towards the Jam Nut to introduce free play in the Clutch Lever. 5. Remove the ¼ – 20 Phillips head screw and Seat. 6. Disconnect negative Battery Terminal. 7. Remove two ¼ – 20 flanged hex nuts from the Stud Plate. Save the Passenger Handrail and two nuts. 8. Remove the Saddle Bags. 9. Remove the Right and Left Side Covers. 10. Remove Inner Tour Pak Molded Liner. 11. Disconnect the Tour Pak wiring. 12. Remove five ¼ – 20 HHCS, ¼ – 20 nyloc nuts, and Aluminum Spacers. 13. Remove Tour Pak from Top Support Tube. 14. Loosen Muffler Clamp on both Mufflers and remove 2 5/16 – 18 HHCS per Muffler. Remove and discard both Mufflers. Save Muffler Clamps. 15. Remove and discard Muffler Support Plates. 16. Remove both ¼ – 20 HHCS and Front Saddle Bag Brackets. 17. Remove the twelve 5/16 – 18 Torx HCS six 5/16 – 18 nuts, and the Left and Right Saddle Bag Guards. 18. Remove the Air Line Junction from the Rear Fender. 19. Disconnect the Rear Lamp Wiring Harness and remove from T-stud Clip.
6 20. Remove two 5/16 – 18 Phillips head screws. Remove the Left and Right Frame Covers. 21. Remove two 5/16 – 18 Torx HCS. Remove and save the Top Tour Pak Support Tube Top. 22. Remove four 5/16 – 18 Torx HCS. Remove the Left and Right Rear Saddle Bag Guard Support Bracket. 23. Remove four 5/16 – 18 HHCS. Remove and save the Tour Pak Support Tube Bottom. 24. Remove and discard the Air Valve Assembly Bracket. 25. Remove four ½ – 13 HHCS and washers. Remove and discard both Rear Air Shock Absorbers. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. NOTE: if ABS equipped refer to separate instructions. 26. Drain all Brake Fluid from the Rear Brake System. 27. Cut and remove Cable ties and un-clamp Wire Harness Loops from the Rear Brake Line along its length, including Clamps on Swing Arm. 28. Remove the 10 – 24 flanged HHCS and Rear Brake Hose Clamp from the Right Rear Fork Bracket. 29. Remove ¼ – 20 SHCS from Rear Stop Lamp Switch Bracket. 30. Remove and discard Banjo Bolt and Crush Washers on Rear Brake Caliper. 31. Remove the Spring Clip and nut from the Rear Axle. 32. Remove Rear Axle and Rear Wheel Spacers. 33. Push Rear Wheel Assembly forward and slip Rear Belt off of the Rear Sprocket. 34. Remove Rear Brake Caliper. 35. Slide Rear Wheel Assembly rearward. Remove one 5/16 – 18 Torx HCS from inside the Rear Fender well. 36. Slide Rear Wheel Assembly forward. Remove two 5/16 – 18 Torx HCS. Remove Rear Fender. 37. Remove and save the two Retaining Washers from the Stud Plate. Remove and save the Stud Plate

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Harley Davidson Road Rod Saddle Bag System Kit INSTALLATION Instructions

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

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Use locktite on all fasteners!! 2. Put bike on lift and place jack under frame. Raise bike to lift rear wheel. 3. If swing arm pivot shaft is drilled and tapped on each end, they need to be redrilled and tapped to 3/8-16 to a depth of _” deep. If you are unable to drill & tap your swing arm pivot shaft, you can purchase one from Cycle Visions (part #CV6121), See Harley Davidson® V-Rod® Service Manual Section 2, Page 2.89 for removal and installation instructions. 4. Remove seat, passenger seat, turn signal module, rear fender cover, turn signal license plate assembly, and rear foot peg assemblies. NOTE: Our bag system will not work with stock exhaust system… we recommend the 2-into-1 Supertrap, or you may use any exhaust system that is lower than the rear axle bolt. 5. Remove the two upper shock bolts. Relocate the shock spacer from the right side to the left side, and use the new spacer supplied on the right side. 6. Install front bag mount between frame and spacer (see Figure 1), reinstall shock bolts and torque to 31-50 lbs. 7. Install lower bag support frame to swing arm pivot shaft using the 3/8″ bolt through rear foot peg clevis and cover (see in Figure 2). NOTE: There is a right and left covers and bag support, install accordingly. Torque to 35 foot lbs. 8. Install rear fender front mounting tabs using 8mm 1.25 x _ and flat washers (supplied in kit) (see Figure 3). 9. Install upright saddlebag support brackets to the lower bag mount assembly and lower fender extension crossover mount. (see Figure 4). Torque to 25 lbs. NOTE: Install crossover mount with gusset facing down. 10. Remove license plate light from your rear turn signal bracket license plate assembly. Install license plate light on our license plate light bracket (see Figure 5). 11. Install the license plate bracket on the inside of the rear fender extension using the top holes of the license plate frame (see Figure 6 & 7). 12. Install fender washers on the inside of the fender extension (see Figure 8). 13. Install upper fender bracket to rear fender extension with a _-20 bolt supplied in kit (see Figure 9). 14. Install rear fender extension with chrome button fitted bolts. (see Figure 10 & 11). 15. To check alignment and fit of rear fender extension reinstall original rear fender. Once you have everything lined up and fitted, remove original rear fender, drill & tap (2) two 5/16 x 18 holes in rear fender support bracket (see Figure 12). 16. Install Harley Davidson® Part #70909-95 and 47449-97 bracket and receptacle on front and rear bag supports (see Figure 13 & 14). 17. Install Harley Davidson® Part #47449-97 bracket with receptable (see Figure 14). Make sure the bolts come from the inside out. This bracket is adjustable for location.

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BMW F 650 CS Rear belt wheel cracks Removal And Installation Manual

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Filed Under (BMW) by admin on 12-11-2010

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Relieve the tension of the toothed belt and lift the belt off the belt wheel (refer to F 650CS Repair Manual, 00.57). 2) Remove 6 screws (see arrow in photo at right). 3) Remove the rear belt wheel. 4) Clean and degrease the tapered bores and the threads of the mounting screws 5) Carefully place the new belt wheel in position on the damper, coat the screw threads with Loctite 243 and hand tighten the securing screws. 6) Tighten the securing screws to the specified torque maintaining a diagonally opposite tightening sequence throughout (Torque to 28 NM, curing time 12 hours). 7) Measure the vertical runout of the belt wheel (refer to F 650 CS Repair Manual, 33.15). 8) Install and adjust the rear drive belt (refer to F 650 CS Repair Manual 00.57 – 00.58) 2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure.

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1987 to Current Harley Davidson Softail (FLST Only) Motorcycle Trike Conversion removal and Installation Guide

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Filed Under (Harley Davidson) by admin on 03-11-2010

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Removal of Original Parts Secure and raise motorcycle 9 to 10 inches using a quality motorcycle lift. Remove the following from the vehicle. See OEM manual for detailed instructions. Items to be retained for reinstallation after modification are noted. • Seat (to be re-installed without modification). • Left and right saddle bags (if so equipped). • Left and right rear crash bars, saddlebag rails (if so equipped). • Left and right passenger foot rests (to be re-installed without modification) • Complete exhaust system (to be replaced with new system). • Rear wheel NOTE: Prior to removing rear wheel, depress foot brake and secure in down position (e.g., zip-tie to floor board). This will prevent fluid flow when rear brake caliper is removed • Remove Rear Caliper (disconnect brake line at caliper) NOTE: Cap line to prevent introduction of dust / debris into line. Remove caliper. • Rear Drive Pulley (1987-99 models to be re-installed without modification). • Rear Fender (2000 and newer models, fender mount plates to be reused). • Swing Arm NSTALLING TRIKE CONVERSION KIT 3.1 Sprockets and Drive Belts Specifications See following table for belt installation (1987-99 will use a 4 tooth longer belt) Note : See OEM manual for belt replacement procedure. Year Drive Sprocket OEM Belt New Belt / Sprocket 1987-92 70 T 132 T 136 1993-94 61 T 128 T 132 1995-99 65 T 130 T 136/70TOEM 2000-06 Champion Sprocket, 70 T 135 T Use OEM 2007 Up Champion Sprocket, 66 T Use OEM 3.2 Install Swing Arm É Noting size and location of bolts, remove Cross Assembly from Champion Swing Arm. Do not discard hardware. Figure 1 3.2.1 1987-99 Model Years • Remove bearings from OEM Swing Arm using OEM shop tools and hydraulic press. Note : Although original bearings can be re-used, it is HIGHLY recommended that NEW bearings be installed to Champion Swing Arm a. b. Press bearings into Champion Swing Arm in the same way as the OEM Swing Arm. Using OEM Spacer Tube and supplied washers (four ¾” flat washers), install Champion Swing Arm using OEM bolt, outside washers and nut. Do not torque pivot bolt nut at this time. Figure 2 Note : Insure belt path is over and under Swing Arm pivot. c. d. Replace cross assembly and hardware (previously removed in step 3.2) to Champion Swing Arm. Note that the 2 upper left hand side bolts are countersunk. Torque pivot bolt to OEM specification

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Harley Davidson Sportster 4 Piston Rear Brake Caliper installation Manual

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Filed Under (Harley Davidson) by admin on 02-04-2012

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Installing Rear Caliper – Sportster Models Removing The Stock Brakes SPORTSTER REAR BRAKE SYSTEM 84 & UP MODELS The basic steps are the same to install a PM rear brake caliper kit on any of the late model Harley Davidson “swingarm” style motorcycles; all require the removal of the rear wheel. Using a suitable lift, raise the motorcycle high enough off the ground to allow you to remove the rear wheel assembly. PHOTO 2 W a r n i n g Center the motorcycle on the lift so that it will not fall while you are working on it. Photo 2: Remove the rear brake caliper assembly by unscrewing the 2 caliper mounting bolts that go through the caliper into the caliper mounting bracket. Lift the caliper up and off the mounting bracket and brake rotor, move the caliper back out of your working area. Don’t remove the brake line from the caliper yet; you will do this just before you are ready to hook it up to the new caliper. The brake pads are held into the caliper mounting bracket by 2 spring clips; slide the brake pads out of the mounting bracket and remove the retaining springs. PHOTO 3 Remove Cotter pin and rear axle nut, slide rear axle completely out. Photo 3: Remove nut from Right rear shock and rotate belt guard up. Slide belt off of pulley and roll rear wheel back 6 – 8″. Photo 4: Remove original caliper bracket from swingarm

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2004 King And CM50 water pump drive belt And pulley alignment & inspection

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Filed Under (Cobra) by admin on 10-11-2010

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It is important to inspect three things on the water pump drive pulley and belt. Inspect 1. That the belt and pulleys are in proper alignment and that the belt is not rubbing on flywheel or edges of the pulleys 2. That the pulleys are not cracked 3. That the water pump impeller pulley fastener is tight and has adequate high strength thread lock agent applied. Below is the proper orientation of the water pump drive pulley, cover, and spacers.

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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

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Harley Davidson Softail Drive Side Brake System Installation Manual

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Filed Under (Harley Davidson) by admin on 30-03-2012

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Removing The Stock Components Although the PM Drive Side Brake System can be installed with the swing arm bolted to the frame, we recommend removing it for better access as well as repainting. Begin by removing rear wheel,stock brake components and belt guard from swing arm. Photo #1 Using supplied 3/4 x 2″bolt,position Drive Side BrakeAssembly on swing arm. Slide assembly to center position of tab and axle spans. Making sure brake mounting tabs are flush with swing arm,snug 3/4 x 2″ bolt to hold assembly and mark swing arm area to be ground Photo #2 . Remove entire assembly from swing arm and thoroughly grind paint away from marked areas Photo #3 . Photo #4 Re-mount assembly to swing arm and slide to rear-most position of both axle and brake mounting tabs. Confirm that brake tabs are flush with swing arm and parallel to each other. Snug 3/4 x 2″bolt and 5/16″socket head cap screws in tabs to hold assembly during welding process. Warning Center the motorcycle on the lift so that it will not fall while you are working on it. Photo #6 Photo #5 Photo #7 Photo #9 Welding Tabs to Swing Arm Note PM recommends all welding be done by a certified welder. Photo #5 Tack weld rear of tabs to swing arm. Avoid excessive welding near brake as- sembly as heat can mar finish. Loosen socket head cap screws and 3/4″bolt,Slide entire assembly to forward most position and re tighten bolts Photo #6 (movement should require minimal effort if tabs are aligned properly) and tack front of tabs to swing arm. Remove brake assembly from swing arm. Weld tabs to swing arm.Verify alignment of tabs, as they must remain parallel to each other. Repaint swing arm and re-install on bike to factory torque specs. Installing Brake Assembly Remove primary bracket from tower assembly (this allows bracket to be installed without having to line up caliper on disc) by removing the three 5/16″socket head cap screws (commonly called allen bolts). Photo #7 Mount rear tire and bolt pulley to rear wheel. Place disassembled bracket against pulley using smaller of two supplied spacers between bracket and pulley. Slide wheel/brake assembly into swing arm. Place large spacer on right side and slide axle in. Do not tighten axle at this point . Photo #8 Slide caliper/tower assembly over disc and install 5/16″x 1″socket head cap screw in center hole to position assembly Photo #9 . Snug, but do not tighten bolt at this point.

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