Gen2/Drive Belt Replacement Procedure

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< Gen2
Revision as of 21:13, 1 August 2018 by BrianTRice (talk | contribs) (move set screw ref)

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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.
  • 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.
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.
Bike on center lift
  1. 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).
  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 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.
  4. Remove the brake pedal:
    This creates clearance for loosening the swingarm bolt above it (might be optional for pre-2015 models).
  5. 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:
    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
  6. X platform: To access the left swingarm bolt, remove the lower left passenger peg bolt (13mm) and remove the grey cover piece.
  7. Remove the left and right swingarm bolts.
    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!
    Remove the left and right swing arm bolts with a 10mm Allen wrench.
    Swingarm Bolt
  8. 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.
    Pulling the Swingarm
    Swingarm Pulled
  9. 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.
  10. Slide the belt over the front sprocket.
  11. Replace the swingarm bolts.
  12. Slide the belt over the rear sprocket.
  13. Set/adjust belt tension accordingly.
  14. Install the rear wheel
  15. Re-check belt tension and alignment.
  16. Re-install the rear brake pedal.
  17. Re-install the rear tire fender.
  18. Extend the sidestand, then lower the bike carefully from the lift onto the sidestand.
2013 S Belt Replacement
2012 DS Belt Replacement, by User:DoctorBass
Swingarm Bolt Set Screw?
Facebook comments by Bobby Loo.