Gen2/Drive Belt Replacement Procedure

From Unofficial Zero Manual
< Gen2
Revision as of 18:50, 9 June 2018 by BrianTRice (talk | contribs) (clarify optional tools' model years)

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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.
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.
  1. Use a lift to raise the bike from the center.
    A sturdy wood crate may work in a pinch. Be safe.
    Bike on center lift
    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).
  2. Pull the wheel off (or slide it forward) by loosening the axle nut with a 27mm wrench.
  3. 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.)
  4. Remove the brake pedal:
    This creates clearance for loosening the swingarm bolt above it (might be optional for pre-2015 models).
    S platform
    1. Remove the right side rear brake pedal (15mm bolt).
    X platform
    1. Remove the pin that attaches the brake pedal to the piston.
    2. Remove the two 13mm bolts that hold the grey piston bracket to the frame, and gently move the whole assembly to the left.
    Rear Brake Lever Bolt
  5. X platform: To access the left swingarm bolt, remove the lower left passenger peg bolt (13mm) and remove the grey cover piece.
  6. 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.
    Swingarm Bolt
  7. 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.
  8. 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.
  9. Slide the belt over the front sprocket.
  10. Replace the swingarm bolts.
  11. Slide the belt over the rear sprocket.
  12. Set/adjust belt tension accordingly.
    Pulling the Swingarm Swingarm Pulled
  13. Install the rear wheel
  14. Re-check belt tension and alignment.
  15. Re-install the rear brake pedal.
  16. Re-install the rear tire fender.
  17. 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.