Gen2/Drive Belt Adjustment

From Unofficial Zero Manual
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Revision as of 04:34, 18 June 2018 by BrianTRice (talk | contribs) (extracted procedure to its own page)

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The official manual has a good procedure from which this is derived. Check that first.

Alignment of the belt is critically tough to get correct, and needs to be done everytime adjusting tension.

Video instruction
How To Adjust Your Belt on Youtube by Mistasam.
27mm hex socket
Breaker bar
Torque wrench set to 75ft/lbs or 102Nm
13mm open-end wrench
  1. Place the motorcycle on a lift or rear stand so the wheel spins freely.
  2. Loosen the rear axle nut on the right side (27mm) with the breaker bar.
  3. Loosen both left and right belt tension jam nuts (13mm) that face forward inside the adjusting gap.
  4. Turn both left and right adjustment nuts (13mm) one quarter turn at a time until belt tension reads in specification.
    • Ensure that the alignment marks on either side of the swingarm indicate that the wheel and belt are aligned.
    • Roll the wheel forward and track it flush with inside of rear sprocket.
    • For proper alignment, the belt will track exactly centered on the wheel sprocket with a 1mm gap to either side of the belt relative to the sprocket.
      Once tension is set and tracking is flush to the inside, tightening the axle nut to 75ft-lbs will tend to nudge belt approximately 1mm to the outside.
    • Measure tension by rolling the wheel forward while plucking bottom side of belt or using tension gauge over several revolutions.
      Expect tension to vary slightly as wheel is rotated because front and rear sprockets are only round to a certain design tolerance.
  5. Check that the belt is aligned with belt tension in the right range.
  6. Re-tighten the left and right jam nuts (13mm).
  7. Tighten the axle nut (27mm) with the torque wrench (to 75ft-lbs).
Belt alignment discussion
How to Adjust Your Zero's Belt
Notes via Shadow