Fate! Sometimes this single word can signal both good and bad outcomes. In my recent situation, fate played out both ways. The last post and video was focused on how to remove, reinstall, and adjust the belt deflection on a Harley touring bike. The idea was to help riders save some money by being able to do the labor themselves. That was going to be the extent of the rear wheel videos, until fate moved in.
While working on the wheel removal/ install for the new Michelin Commander II tire that I got from Get Lowered Cycles, I spotted a problem. Fate had popped a rock or something into the tiny focused path of my drive belt. The object caught between the belt and sprocket, tearing the outer edge of the belt, crushed, and tore one of the teeth as well. This is where fate said “a major tear down was coming to replace it”. This is where fate said “I didn’t leave you stranded on the side of the road, I got you home”. This is where fate said, “this will be a fantastic helpful video series”…..Fate came bearing both good and bad tidings this time.
Replacing the drive belt is a huge undertaking. This is one of those tasks you may as well just settle into the fact that its a lot of work and will take a lot of time. And on the flip side, will save you a lot of money. When you add up dealership labor cost and parts you will be looking at over $1000 from a damaged drive belt. That is a lot of change. And if you managed to get the bike home dependent upon the amount of damage, towing fees may come into play as well.
I knew this would make for a great video but there was so much work involved it was going to be long. Too long for most people to watch all the way through. I decided to break it into four parts instead of one long video. Add in the wheel removal/ install and the drive belt deflection adjustment and it comes out to 6 videos in total which is manageable. The process for replacing the drive belt involves removing the rear wheel, removing the rear fork, removing the primary, replace the belt, assemble the primary, assemble the rear fork, install the rear wheel, and adjust the drive belt tension.
Fork and Primary removal
When I found the damage I contacted Get Lowered Cycles to see about parts. At this point I was stuck. There could be no riding the bike so I had to get parts and get them fast. We were heading into a holiday weekend which would give me an extra day if necessary to perform the repairs. Otherwise because of work, it would be another full week before I could perform the repairs, and another week after that to take the bike out for a ride. Get Lowered Cycles came through with amazing customer service and delivery. I received the parts within 2 days of confirmation and was able to work on the bike over the extended holiday weekend. They have been a fantastic company to work with and I would encourage you to try them out for your next purchase.
Completion of breakdown including Inner Primary Cover- Ready for Final Drive Belt Replacement
You will need some specialty tools for this repair. As I have said in the past, the cost of the tools is far less than paying a dealership and then you have the tools for any future work. Here is a list of specialty tools you will need outside of standard tools like screwdrivers and socket sets. I also stress as always, have the service manual specific to your bike! This will be necessary for process and torque specifications:
Motorcycle Jack Stand or lift
Air impact wrench- For removing the fork bolts
T70 Torx- For removing the compensator sprocket
Torque wrenches that will do 12 to 175 foot pounds. This will require multiple wrenches since the torque range necessary is so varied
Large Breaker Bar
Primary locking tool- or make one out of wood
Large 1 3/8 inch box wrench or a large crescent wrench will work. This is for the welded axle nut when finalizing the install of the wheel
Large 36mm socket to torque the axle nut- Multiple large sockets would be best to ensure the correct fit
Snap Ring Pliers- for clutch basket removal
Blue and Red Loctite
Silver anti-seize lubricant
Various sizes of Allen and Torx Sockets
Long stem Allen wrench to remove the starter
Belt Tension Tool
As for the parts the list is quite short:
Final Drive Belt
Sealing fasteners for the inner primary
Primary Chain Case Cover Gasket
Crank Case Gasket
Inner Primary Lip Seal
2 Quarts Primary fluid
The video below begins the playlist with rear wheel removal, then moves on to rear fork removal, primary removal, primary assembly, rear fork assembly, and adjusting drive belt deflection. You will have to go back to the rear wheel removal/ install video after assembling the rear fork.