v star 650 shaft to belt conversion

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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.

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

BMW F650 CS Front belt wheel not correctly secured

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Filed Under (BMW) by admin on 23-11-2010

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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 2.3 Wear check gearbox main shaft- It is extremely important that the techni- cian always check that the dimensions of the gearbox main shaft splines are to specification before proceeding with the installation of a new front belt wheel. This note only applies to motorcycles with accumulated mileage, not to new motorcycles from the crate. If the visual inspection was satisfactory and the main shaft was not replaced for visual damage, a main shaft wear check will be necessary. This check requires the use of BMW Special Tool # 23 4 571 . The adapters are designed for micrometer gauges with stud diameters from 6.35 mm to 6.6 mm. Do not use cellulose-lacquer thinners to clean the adapters as there is a risk of damaging the measuring instruments. Make sure that the micrometer gauges and the adapters are perfectly clean

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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