Difference between revisions of "Gen2/Drive Belt Replacement Procedure"
From Unofficial Zero Manual
< Gen2
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| − | This covers replacement of the [[ | + | This covers replacement of the [[Drive Belt|drive belt]] on 2012+ S and X platform models. |
| − | : It requires disconnecting the [[ | + | : It requires disconnecting the [[Gen2/Swingarm|swingarm]] which a lift makes easier, so is not an easy roadside operation. |
<onlyinclude> | <onlyinclude> | ||
| Line 6: | Line 6: | ||
: 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. | : 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 | + | ;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: | * [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}} | *: {{#ev:youtube|9o0qhMdAKDc}} | ||
;Tools | ;Tools | ||
| − | * [[ | + | * [[Lift|Center lift]]. |
* 27mm socket. | * 27mm socket. | ||
* 3mm Allen key. | * 3mm Allen key. | ||
| Line 28: | Line 30: | ||
: The following steps are suited to garage locations. | : The following steps are suited to garage locations. | ||
: [[file:Onlift.jpeg|thumb|Bike on center lift]] | : [[file:Onlift.jpeg|thumb|Bike on center lift]] | ||
| − | # Use a [[ | + | # Use a [[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). | ||
| Line 53: | Line 55: | ||
#: Then remove the bolts by holding the inside nut with a 24mm wrench, and a 10mm hex on the head. | #: 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! | #:: 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+ | #;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. | ||
| Line 65: | Line 69: | ||
# Replace the swingarm bolts. | # Replace the swingarm bolts. | ||
# Slide the belt over the rear sprocket. | # 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-check belt tension and alignment. | ||
# Re-install the rear brake pedal. | # Re-install the rear brake pedal. | ||
Latest revision as of 23:56, 29 March 2020
This covers replacement of the drive belt on 2012+ S and X platform models.
- It requires disconnecting the swingarm which a lift makes easier, so is not an easy roadside operation.
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
- How To: Replace Your Zero Motorcycle Belt by NewZeroLand on YouTube:
- Zero emergency toothed belt by UW4E on YouTube:
- Tools
- 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.
- 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.
- 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.
- 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 and alignment accordingly.
- 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
- 2013 S Belt Replacement
- 2012 DS Belt Replacement, by User:DoctorBass
- Swingarm Bolt Set Screw?
- Facebook comments by Bobby Loo.
