Difference between revisions of "Gen2/Drive Belt Replacement Procedure"
From Unofficial Zero Manual
< Gen2
BrianTRice (talk | contribs) (clarify optional tools' model years) |
BrianTRice (talk | contribs) (thumbnail photo layout) |
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:: However, no effective procedure has been described for the process. | :: However, no effective procedure has been described for the process. | ||
: The following steps are suited to garage locations. | : The following steps are suited to garage locations. | ||
| + | : [[file:Onlift.jpeg|thumb|Bike on center lift]] | ||
# Use a [[Unofficial Service Manual#Lift|lift]] to raise the bike from the center. | # Use a [[Unofficial Service Manual#Lift|lift]] to raise the bike from the center. | ||
#: A sturdy wood crate may work in a pinch. Be safe. | #: 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). | #: 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 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. | + | # 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 just removing the screws on the left side to allow lifting the fender up enough to get the belt under. | ||
# Remove the brake pedal: | # Remove the brake pedal: | ||
#: This creates clearance for loosening the swingarm bolt above it ''(might be optional for pre-2015 models)''. | #: This creates clearance for loosening the swingarm bolt above it ''(might be optional for pre-2015 models)''. | ||
| Line 32: | Line 33: | ||
## Remove the pin that attaches the brake pedal to the piston. | ## 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. | ## 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|Rear Brake Lever Bolt]] | + | #: [[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. | # '''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. | # Remove the left and right swingarm bolts. | ||
| Line 41: | Line 42: | ||
#;2014+ | #;2014+ | ||
#: Remove the left and right swing arm bolts with a 10mm Allen wrench. | #: Remove the left and right swing arm bolts with a 10mm Allen wrench. | ||
| − | #: [[file:Swingarmbolt.jpeg|Swingarm Bolt]] | + | #: [[file:Swingarmbolt.jpeg|thumb|Swingarm Bolt]] |
# Hang the swing arm with a strap on the tail section. | # 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. | #: 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. | # 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. | #: 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. | ||
| Line 51: | Line 53: | ||
# Slide the belt over the rear sprocket. | # Slide the belt over the rear sprocket. | ||
# [[Unofficial Service Manual#Belt_Adjustment|Set/adjust belt tension accordingly]]. | # [[Unofficial Service Manual#Belt_Adjustment|Set/adjust belt tension accordingly]]. | ||
| − | |||
# [[Unofficial Service Manual#Rear_Wheel_Install|Install the rear wheel]] | # [[Unofficial Service Manual#Rear_Wheel_Install|Install the rear wheel]] | ||
# Re-check belt tension and alignment. | # Re-check belt tension and alignment. | ||
Revision as of 18:55, 9 June 2018
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.
- Tools
- Center lift.
- 27mm socket wrench.
- 3mm Allen key.
- 10mm Allen key wrench.
- 15mm socket wrench (S models).
- 13mm socket wrench (X models).
- Torque wrench capable of setting 75ft-lbs.
- 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.
- 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 just removing the screws on the left side to allow lifting the fender up enough to get the belt under.
- Remove the brake pedal:
- This creates clearance for loosening the swingarm bolt above it (might be optional for pre-2015 models).
- S platform
- Remove the right side rear brake pedal (15mm bolt).
- 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.
- 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.
- 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!
- 2014+
- Remove the left and right swing arm bolts with a 10mm Allen wrench.
- 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.
- 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.
- Set/adjust belt tension accordingly.
- Install the rear wheel
- Re-check belt tension and alignment.
- Re-install the rear brake pedal.
- Re-install the rear tire fender.
- Lower the sidestand and then lower the bike carefully from the lift onto the sidestand.
- References
- 2013 S Belt Replacement
- 2012 DS Belt Replacement, by User:DoctorBass
- Facebook comments by Bobby Loo.
