The lower rear holes in the gasket often don't align correctly without a bit of help from a screwdriver....take your time and get it right




Tighten all the primary chaincase screws correctly

Refit the drain plug and refill the primary with 1130cc of primary oil and do it before you refit the chain adjuster inspection cover



Adjust the clutch cable so there is 1-2mm of slack at the lever



Get the bike back on its wheels, bounce the suspension a few times, check wheel alignment and adjust the belt as per the manual



Tighten the axle to the correct torque and re-check the belt tension



Then eat Bran Flakes with Apple and Rasins while someone road tests the bike....



These pics show why Dr Phil wanted his belt changed today





There were two holes and a tear.....I think he had his money's worth from that belt

So that's how its done.....if you need more info than is in these posts and a Haynes manual then you shoudln't attempt the job but its not that difficult if you keep your head.

We took 2 hours to do the job.....it will take longer to clean up the mess after I stood in the oil bucket trying to get a decent pic of Dr Phil working on the bike than the job took

I hope you found this useful and it has given you the courage to save a few dollars on doing it yourself......if it has had the opposite effect and made you realise you don't want to attempt it then I applaud you for being honest with yourself.

Love, Spanners39

 

On my '88, I had to remove the swingarm, well, drop it a little to get the belt out. Something else about two screws you made a special tool for is new to me also. But other than that, that's how I did it too! Thanks for the directions in color!!

 

Wow...that looks like a big job. How many miles were on Phil's belt? How old is his primary chain? Even though it wasn't problematic now, why not just change the shift seal while you're right there?

 

Belt had 50K on it and holes, and tears....primary chains never wear out so it isn't an issue and shift shaft seals go a very long time too......he will likely need a new lever before the seal gives any trouble.

 

Great series of threads. Thanks Spanners and well done to the rest of us for staying the course! I must confess that job is over the threshold of what I personally will tackle, but then I have my own 'Spanners' just a few miles away (ex-Harley mechanic and Harley track racer).

 

Thank you for posting this. It was very informative!

 

Very cool, I can do that, just never been in there before.

 

Spanners, can I make a suggestion? This thread looks likely to leave the others behind. How about posting links in each one, so members can slip seamlessly between them?

 

Will do

 

Done.................