Tools I used:
- a bunch of allen wrenches (t-handle, L-bar and socket)
- torque wrench
Learning and informational resources:
I would not have been as confident I could do this service myself if it was not for the ca-cycleworks videos. Thanks Chris!
http://www.youtube.com/watch?v=9vzPZ84ZRjU
Here are the things I learned:
With the covers off and plugs out. I spun the back wheel in top gear to line up the pulleys.
Belt Replacement - Removal Steps:
- Remover sparkplugs
- Put finger over the plug hole on the horizontal cylinder by the front wheel once you feel pressure pushing at your finger then line up the pulley marks.
- Double check everything lines up.
- Loosen the tensioner bolts
- Slip horizontal belt off the pulley on the cam
- Remove belt
- Slip vertical belt off the pulley on the cam
- Remove belt
Belt Replacement - Installation Steps
- The crank pulley should be in the same spot it was when you removed the belts (check the mark lines up)
- Use you fingers to line up the cam pulley with the mark
- Slip vertical belt on to the pulley on the cam
- Carefully get the belt around the crank pulley without letting the cam pulley move.
- Pull the tensioner in and lightly tighten to hold it in place till you check the tension
- Line up the horizontal cam pulley
- Slip belt over it and the slip belt over the cam pulley
Belt Replacement - Setting Tension on the belts
- Set the tension by feel
- Make sure you can push down on the belt and it will move off the idler.
- Use a 5mm and 6mm hex wrench. The 5mm should slide between the belt and idler and the 6mm should be pretty hard. (watch video)
- I also used the 45 degree method. I read you should be able to twist the belt 45 degrees
I feel that with so many people using the 5mm hex method I should be fine. The belts that where on there were looser but close to the hex tension.
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