View source for Gen2/Drive Belt Replacement Procedure

This covers replacement of the [[Drive Belt|drive belt]] on 2012+ S and X platform models.
: It requires disconnecting the [[Gen2/Swingarm|swingarm]] which a lift makes easier, so is not an easy roadside operation.

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Ask your dealer/Zero before replacing it.
: They may perform it under warrantee if it happened prematurely; and they'll likely want to understand how and why it broke, anyway, for quality reasons.

;Video Guides
* [https://www.youtube.com/watch?v=zGi19IYRnrc How To: Replace Your Zero Motorcycle Belt] by [https://www.youtube.com/channel/UCdEMqkiM5I-98gxZKJXQ65Q NewZeroLand] on YouTube:
*: {{#ev:youtube|zGi19IYRnrc}}
* [https://www.youtube.com/watch?v=9o0qhMdAKDc Zero emergency toothed belt] by [https://www.youtube.com/channel/UC6z8t3aHDKTDYJbW6_pSqsA UW4E] on YouTube:
*: {{#ev:youtube|9o0qhMdAKDc}}

;Tools
* [[Lift|Center lift]].
* 27mm socket.
* 3mm Allen key.
* 10mm Allen key socket
*: Ensure at least 1" depth and a ⅜" drive sufficient to handle swingarm pivot bolt torques.
* 15mm socket wrench (S models).
* 13mm socket wrench (X models).
* Torque wrench capable of setting 75ft-lbs and driving the 27mm socket and 10mm Allen key.
* 2012-2013:
** 2.5mm Allen key.
** 24mm socket wrench.

;Procedure
: '''NOTE:''' For roadside belt swaps, particularly for an FX or FXS, setting the bike on its side should be possible for this work.
:: However, no effective procedure has been described for the process.
: The following steps are suited to garage locations.
: [[file:Onlift.jpeg|thumb|Bike on center lift]]
# Use a [[Lift]] to raise the bike from the center.
#: A sturdy wood crate may work in a pinch. Be safe.
#: If the lift can be adjusted, lift the rear wheel just off the ground for ease of removal and replacement (lower than depicted but not in contact).
# Pull the wheel off (or slide it forward) by loosening the axle nut with a 27mm wrench.
# Pull off the rear tire fender by taking out the 4 hex bolts securing it with a 3mm Allen wrench.
#: You can get away with removing only the left-side screws, to allow lifting the fender up enough to get the belt under.
#: The right side fasteners also anchor the brake line to the rear calipers and a grounding strap, so mind them for re-attaching in the same way.
# Remove the brake pedal:
#: This creates clearance for loosening the swingarm bolt above it ''(might be optional for pre-2015 models)''.
# Get the rear brake pedal out of the way of the right side swingarm pivot bolt.
#: '''S platform:''' Use the 15mm hex socket to loosen or remove the bolt forming the pedal pivot.
#: '''X platform:'''
#:# Remove the pin that attaches the brake pedal to the piston.
#:# Remove the two 13mm bolts that hold the grey piston bracket to the frame, and gently move the whole assembly to the left.
#: [[file:Rearbrakebolt.jpeg|thumb|Rear Brake Lever Bolt]]
# '''X platform:''' To access the left swingarm bolt, remove the lower left passenger peg bolt (13mm) and remove the grey cover piece.
# Remove the left and right swingarm bolts.
#;2012-2013
#: Remove the set screws from the swingarm bolts on both sides with a 2.5mm Allen wrench.
#:: The set screw is very difficult to find.
#:: It is located in one of the sides of the 24mm hex nut, perpendicular to the long axis of the 10mm allen bolts.
#:: It is actually on the edge of the nut.
#:: The best way to locate it is to use a small mirror and a strong flashlight.
#: Then remove the bolts by holding the inside nut with a 24mm wrench, and a 10mm hex on the head.
#:: This was the hardest step, because there is not a lot of room to manipulate in the rear assembly - especially with a 24mm wrench! 
#;XU-2013
#: sane as above,  but needed a 23mm wrench and a 2mm Allen wrench instead of the 24mm wrench and 2.5mm allen wrench
#;2014+
#: Remove the left and right swing arm bolts with a 10mm Allen wrench.
#: [[file:Swingarmbolt.jpeg|thumb|Swingarm Bolt]]
# Hang the swing arm with a strap on the tail section.
#: The swingarm will pull back enough for the belt to fit through the frame.
#: [[file:Swingarmpull.jpeg|thumb|Pulling the Swingarm]] [[file:Swingarmpulled.jpeg|thumb|Swingarm Pulled]]
# Check the front sprocket for debris, and clean it with a firm but non-abrasive brush.
#: If the sprocket is damaged somehow or the teeth are too worn to engage the belt, get it replaced to avoid damaging the new belt.
#: The rear sprocket regularly deserves the same treatment.
# Slide the belt over the front sprocket.
# Replace the swingarm bolts.
# Slide the belt over the rear sprocket.
# [[Gen2/Drive Belt Adjustment|Set/adjust belt tension and alignment accordingly]].
# [[Gen2/Rear Wheel Install|Install the rear wheel]]
# Re-check belt tension and alignment.
# Re-install the rear brake pedal.
# Re-install the rear tire fender.
# Extend the sidestand, then lower the bike carefully from the lift onto the sidestand.

;References
: [http://electricmotorcycleforum.com/boards/index.php?topic=3530 2013 S Belt Replacement]
: [http://electricmotorcycleforum.com/boards/index.php?topic=3217 2012 DS Belt Replacement], by [[User:DoctorBass]]
: [http://electricmotorcycleforum.com/boards/index.php?topic=8184 Swingarm Bolt Set Screw?]
: Facebook comments by Bobby Loo.
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[[Category:Procedure]]
[[Category:Repair]]