Just did mine yesterday, did the same thing. Once you have the crank
bolt broke loose, I
took a pair of pliers and a long screw driver, and turned
the cam pulley( left side pulley
as you face the bike) and reposition the pulley to the
original starting spot. The lable(UP)
on right and left pulleys should be horizontal and the
T1 on the crank should be back at
the original starting position. A little tip. I took a
marking crayon and put refrence marks
on all pulleys and belts to make sure eveything would
be back to the original spots.
Worked great for me. Good luck, ride safe.
Make sure you get it right and if it you have a doubt, pull the plugs
and rotate the engine by
hand slowly and make sure there is not any interference.
With the plugs out you don't have
to worry about compression turning the engine while you
have the belts off. A friend just
bought 12 valves and 2 headgaskets for $527.00. Exhaust
valves are $47 and change each,
intake are $28 and change each. Head gaskets and tax made
up the rest. This did not
include installation. Mark the belt position on the pulleys
before you start. Whiteout like
you use when typing works well. Be sure you notice the
dimple on the index wheel when
you put it back together or the timing marks will be off.
Trigger wheel is a 'best bang for
the buck' improvement.
ride safe
Bob
I know there have neen a lot of these messages, but I thought my experience may assist.
I used the 5th gear & foot brake method to loosen the crank bolt and it worked fine.
Also I used whiteout to mark the belt and pully position
(both) so there was no way I could
get it wrong. Appenently thats what qualified mechanics
do, so I was told by my mechanic
son.
When I removed the marker plate off the drive pully I found
the locating spigot had been
sheared off during the original tightning. To repair this
I drilled out the marker plate in the
appropriate location and got a 1/8 drill bit and broke
of 1/4 inch from the end with a
hammer and vice. Then ground it down to the correct length.
It fitted quite ok and the flat
washer laps over it so it has nowhere to go.
The rain is pissing down here so I have not taken the valk
out on the road yet. But it starts
and idels ok..
Bruce..
Here's a tidbit for people like me who are just mechanical enough to
get in trouble. Putting
my trigger wheel on last night using the 5th gear method
and when I loosened the crank
bolt the pulleys all moved maybe an eighth turn. No problem
I thought since they all moved
together and I went ahead with the operation. Sometime
between putting the new wheel
on and reaching for the belt I heard a small noise and
then the belt marks would not line up
anymore. Apparently it was just enough off TDC to let
compression turn the left pulley
some. After the panic attack wore off I turned the pulley
back to where the belt marks
matched up, put it all back together, gritted my teeth
and hit the starter. No parts flew so I
guess I am ok.
Lesson learned: If the pulleys move while loosening the
bolt, move them back before
proceeding.
You will also get a noise if you have overtighened the timing belt.
Position the tensioner so
that when you push in on the long side of the belt with
light to moderate pressure you can
depress the belt 3/8 to 1/2 inch.
You can't put the drive gear on "indiscriminantly"...it's keyed to the
crankshaft end. You
could have put it on backwards with the hole for the guide
plate pin engagement facing the
rear of the bike. That would be a major problem. So if
you aren't sure you have to take the
timing belt cover back off and check. If your drive gear
and cam gear index marks don't
both line up with their respective index marks after rotating
the engine over you have extra
slack in the "pull" (tight) sides of the belts. The "pull"
side is on the bottom of the right belt
and on the top of the left belt. (Right and left from
the rider's perspective). You have to
get the belts tight to the point where one more tooth
tighter just can't be made to happen
with the gears at their index marks.
BUT!! the little cover plate with the timing marks
: has a locator pin that sticks into a hole in the
: front belt sprocket and Guess What? the pin
: sheared off. From the looks of it, the plate had
a
: couple of cracks around the pin, which is probably
: related to the shearing, and I'm glad to find
it
: now and not halfway to Sturgis.
Jim,the belt should be tensioned as follows,turn the engine over by
hand and feel the
tension at the pull side(side without the tensioner)and
you will notice the belt going from
tight to loose,when the belt becomes tight loosen
the lock bolts on the tensioner and
de-tension the belt by pushing the roller away from
the belt then let the spring on the roller
tesion the belt,do not push or help it in any way,if
you do when the engine gets hot you will
get a chirping noise indicating the belt is too
tight. Let me know if you have any further
problems.
Get a $20 bar & needle style 3/8" drive torque wrench from Sears.
Good from 0-75 LB/ft.
That will satisfy ANY need for a torque wrench on your
bike (you only need the BIG one
if yer working on a semi wheel)
Put your bike in gear. Pull the timing cover. Get a sharpie
permanent marker and before
you do ANYTHING else, mark your belts and pulleys with
index marks with the marker.
Make a mark that goes off the belt and onto each of the
three pulleys. Mark the tensioner
position the same way then loosen one (I think it's the
left one)
Sit on the bike and jam the rear brake (you need a helper).
Squirt a little WD on the center
nut and take it off. Swap out the wheels. Wipe the WD40
off good. and make sure you
put all the pulleys back at your index marks matching
up with the belt. Jam the brake and
tighten. Then index the tensioner and tighten.
Wasn't that easy? We did not even align the pulleys to
their UP marks, we just used our
own index marks. You are guaranteed not to miss a tooth
if you index first.
Ken: Drive pully goes back on with hole facing out. Timming guide plate
has a projection
on back that aligns with hole in drive pully. Things
might move a little when you torgue the
bolt. Just as long as the belt does't jump a tooth
you should be ok. You can turn engine
counterclock wise just like when you started and
make sure all marks still line up. Hope
this helps.
Charlie, you are right on all counts but remember two things. (1 When
the "up" marks are
right side up the index line below the "up" on the outer
side of the driven pulleys still have
to point right at their index arrows on the outside edges
of the timing belt case, and 2)
when you have the timing belt case front cover off there
is no index to check the T1.2
mark on the plate on the front of the front drive pulley.
So, get on the driver's left side of
the bike and look at the edge of the rear drive pully.
There is an index mark on it that
aligns with a corresponding mark on the rear timing case
when the drive pulleys are at
T1.2. Voila! Put the belt on without slack, set the tension
and rotate the engine over
clockwise until that rear index lines up again. Check
your cam driven gear indices to be
sure they still point right to the index arrows in the
outer edges of the case. If they do, and
you have properly torqued everything you reassembled...button
'er up.
My book says 54 ft. lb.and 19 ft. lb for the tensioner bolts.
Before I retightened the crank bolt, I made sure all the marks that
I had made on the
pulleys and belts lined up. On the crank, make sure
the timming wheel(T1), is back to the
original starting position. Then you can torque
to 59ftp the crank bolt. This procedure
worked great for me, no problems.The instructions
were off of the web page for the
Trigger Wheel, which were very helpful.Good luck,
ride safe.
The directions should mention the dimple on the timing washer lining
up with the pulley...
IMHO the hardest thing about the job is getting the new
belt on .. that tensioner screwed
me up even after i disengaged the spring...
When we did my brother's bike, we simply loosened the nut holding the
pulleys and
trigger wheel (by putting the bike in gear - third
works fine by the way), removed the
right belt, did the swap, THEN... aligned the cam
pulley and crank pulley... voila...
everything fits.
Second...Mark the wheel and the pulleys!!...yes, pulleys!!...i had mis-understood
some
of the postings and marked the 2 outside pulleys, what
i mean is, mark
the small center pulley before pulling the belt...it made
absolutely no sense to mark my
outside left pulley with no marking on the center one...what
a goof-ball!!!
Thirdly, read lamomnts directions and memorize!!
Fourth, the belt comes off somewhat hard but goes on much
harder imho...i took the
spring off the tensioner just to get that thing out of
the way ... otherwise my valve train
would turn on me as i tried to monkey with the belts,
got some pressure on the belt from
the tensioner and ultimately turn that valve system a
bit...THIS IS WHERE THE
PROPER MARKINGS WOULD HAVE BEEN A GREAT HELP!!!!!!
The belt is a royal pain to put on...be prepared..(unless
someone has a secret i don't
know..of course, lately, my incompetence with hand tools
seems to have been at an
all-time high!!...lol)
The timing marks are very accurate, there is a bit of play
there, but when everything is
perfect they all lineup great...with the front wheel in
the way you may not be able to see
the right pulley all that well on the inside but as long
as it is correct on the outside, along
with the center pulley lined up with the casing and the
right pulley 'dead-nuts' on it's
inside mark everything will go back together as it should....i
tested things out by hand
cranking the motor a few times to ensure i didn't meet
any resistance....
BTW, don't forget to hook the spring back up on the tension
pulley...i already had
enough tension on the belt i didn't feel the need to introduce
any more (of course i only
have 8k miles on the bike also...)
Moment of truth....start her up and smile...
install the front dust guard (yes the bolts are almost
ALL different!!) and ride her with
the biggest S%^t-eating grin you will ever have!!
I didn't watch for any index points on the washer in regards
to the dimple on the pulley ,
but i'll take lamonts advice and not worry 'bout it!
First; did you face the trigger wheel with the
OUT mark facing out? If so then lets do a
quick timing belt check, put the crank timing
mark to the T1-2 and alighn it with the mark on
the crankcase on the right of the crank
pulley(facing from the front of the engine),both
cam pulleys should have the UP marks
horizontal and facing so you can read the UP marks
without standing on your head
:^)and the cam pulley marks(slots) should alighn
with the backing plates arrows,if you
are unsure if you are off a tooth,use a thin screwdriver
and line up the screw driver one
tooth above and below the backing plate marks to
see if you are in fact off.Hope this
helps,if your sure about the timing belts perhapps
the main jets in the carbs are too
big,stock is #100 and with a K+N and pipes usually
#105 to #108 will work pretty
good depending what elevation you are at.
Installed wheel and now have about 500 miles since then. Runs great,cranks
better, and
mpg has improved. Took cover off to check belt tension
and lined up the up marks on
the cam pulleys and noticed the washer on the crank bolt
with the marks on it did not
line up with the mark on the case.
Marked the belts so they went back in same place.The wheel
and the cam pulley were
keyed so they went back in same place, but don't recall
if the indexed washer[plate]was
keyed. Is it possible this moved when I tightened the
bolt?
It runs so good I don't want to mess with it.
The plate or washer behind the left side cam drive oulley
mark still lines up with mark on
case.
Yes the index washer is keyed. It has a pin on the backside. I wouldn't
worry about it till
you get ready to adjust your valves.
I agree on the marking of the belt as any added measure to insure that
things are indeed
aligned is good. With regard to the belts, I layed on
the ground and never took the belt
off, as I held the belt on the sprocket with my left hand
I removed the bolt from the
crank and then the trigger wheel and had my helper hand
me the new trigger wheel and I
slipped it on and then slipped the crank sprocket back
on and saw the marks were lined
up and tightened the bolt. Simple!
More importantly, people who are contemplating the procedure should
heed the advice
of those who have done it and ensure that both pulleys
get marked in 2 locations and to
mount the washer in alignment with the dimple...