N
n55w131
Active member
For those of you who need to install a new quickdrive belt, I highly recommend you obtain or make a set of install tools to aid the process. Its very difficult to install without some sprocket install guides.
Here is how you can make a set if you have a lathe or know someone who does that can help you.
To make two tools you will need a piece of stock that is 3" to 4" long and needs to be 22mm in diamter, you can obtain a piece of stock that size or machine it down from 7/8" or 1" stock. The stock material should be hard steel like 4140 or pin stock.
After ariving at 22mm, drill a center hole 10mm (13/32 is close enough)through the stock for at least 2".
Next put a taper approximatly 5mm from the end, from the 22mm surface down to about 17mm to obtain a shallow angle to the end of the tool of 30 degrees or so. You need a shallow angle to be able to slip the sprocket on and over the tool and onto the splines of the shaft. The actual angle is not crititcal.
Polish the tool and taper with coarse and fine emery cloth before cut-off. The smoother it is the better the sprocket will slide up and over it.
The tool should then be cut off about 21mm long.
This results in about 16mm of 22mm surface and 5mm taper.
The hole is for a 10mm x 1.25 x30mm metric cap screw. You can also use a 10mm x 1.25 x30mm metric bolt, but a round head cap screw works better.
Belt Removal/Install Instructions: Remove the existing bolts and cup washers, then remove both sprockets and belt together. Next install the two tools using the hex cap or bolt. Note: they dont have to be installed very tight.
Put the new belt on the sprockets, observing the correct orientation of the lips on the sprockets (upper sprocket lip is out and lower sprocket lip is in) and the arrow on the belt facing forward towards the front of the machine.
Work both the top and bottom sprockets on together, staring with the bottom sprocket on first, just starting in on the splines, then work the top sprocket on the splines. You must alternate bottom and top, moving them on a bit at a time, too much and the belt and sprockets will bind. There is no stretch in this belt so it is difficult to get them started even with the aid of the tools.
Once you have both sprockets on all the way, remove the two install tools and utilize the two new bolts that came with the quickdrive belt kit. Orientate the domed washers with the domes out and torque the new bolts to 30ft lbs.
Make sure you break the belt in properly. The first 100 miles is the break-in period. When the belt is new it is best to warm the belt up on a short no heavy load ride and let it cool down. Do this several times. After that make sure to warm the engine up before riding and avoid cold starts. Also avoid power on landings and loaded starts (track stuck, machine stuck, etc) that would cause excessive load on belt the drive system. During this break-in period the belt will shed its mold release material which is normal. Just clean it off with a dry cloth. Never use any cleaning agent on the belt.
Hope this helps..
Cheers
Here is how you can make a set if you have a lathe or know someone who does that can help you.
To make two tools you will need a piece of stock that is 3" to 4" long and needs to be 22mm in diamter, you can obtain a piece of stock that size or machine it down from 7/8" or 1" stock. The stock material should be hard steel like 4140 or pin stock.
After ariving at 22mm, drill a center hole 10mm (13/32 is close enough)through the stock for at least 2".
Next put a taper approximatly 5mm from the end, from the 22mm surface down to about 17mm to obtain a shallow angle to the end of the tool of 30 degrees or so. You need a shallow angle to be able to slip the sprocket on and over the tool and onto the splines of the shaft. The actual angle is not crititcal.
Polish the tool and taper with coarse and fine emery cloth before cut-off. The smoother it is the better the sprocket will slide up and over it.
The tool should then be cut off about 21mm long.
This results in about 16mm of 22mm surface and 5mm taper.
The hole is for a 10mm x 1.25 x30mm metric cap screw. You can also use a 10mm x 1.25 x30mm metric bolt, but a round head cap screw works better.
Belt Removal/Install Instructions: Remove the existing bolts and cup washers, then remove both sprockets and belt together. Next install the two tools using the hex cap or bolt. Note: they dont have to be installed very tight.
Put the new belt on the sprockets, observing the correct orientation of the lips on the sprockets (upper sprocket lip is out and lower sprocket lip is in) and the arrow on the belt facing forward towards the front of the machine.
Work both the top and bottom sprockets on together, staring with the bottom sprocket on first, just starting in on the splines, then work the top sprocket on the splines. You must alternate bottom and top, moving them on a bit at a time, too much and the belt and sprockets will bind. There is no stretch in this belt so it is difficult to get them started even with the aid of the tools.
Once you have both sprockets on all the way, remove the two install tools and utilize the two new bolts that came with the quickdrive belt kit. Orientate the domed washers with the domes out and torque the new bolts to 30ft lbs.
Make sure you break the belt in properly. The first 100 miles is the break-in period. When the belt is new it is best to warm the belt up on a short no heavy load ride and let it cool down. Do this several times. After that make sure to warm the engine up before riding and avoid cold starts. Also avoid power on landings and loaded starts (track stuck, machine stuck, etc) that would cause excessive load on belt the drive system. During this break-in period the belt will shed its mold release material which is normal. Just clean it off with a dry cloth. Never use any cleaning agent on the belt.
Hope this helps..
Cheers
