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Gen2/Drive Belt Adjustment

2,745 bytes added, 00:05, 30 March 2020
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;Goal
: Align and set belt tension to avoid bad wear and early breakage.
: Alignment of the belt is critically tough to get correct, and needs to be done everytime adjusting tension.
: Zero's [[Official Owners Manual]] has a good procedure from which this is derived. Check that first.

; Video instruction
: [https://www.youtube.com/watch?v=mab3a7MWrpY Zero SR: How To Adjust Your Belt] on Youtube by NewZeroLand:
:: {{#ev:youtube|mab3a7MWrpY}}

; Tools
: 27mm hex socket
: Breaker bar
: Torque wrench set to 75ft/lbs or 102Nm
: 13mm open-end wrench
; Instructions
# Place the motorcycle on a [[Lift]] or rear stand so the wheel spins freely.
# Loosen the rear axle nut on the right side (27mm) with the breaker bar.
#: [[File:Rear Axle Nut and right adjustment bolt.jpeg|200px|Rear Axle Nut and right adjustment bolt]] [[File:Rear Axle Spacer and left adjustment bolt.jpeg|200px|Rear Axle Spacer and left adjustment bolt]]
# Loosen both left and right belt tension jam nuts (13mm) that face forward inside the adjusting gap.
#: [[File:Rear Axle Nut and right adjustment bolt - loosened.jpeg|200px|Rear Axle Nut and right adjustment bolt - loosened]] [[File:Rear Axle Spacer and left adjustment bolt - loosened.jpeg|200px|Rear Axle Spacer and left adjustment bolt - loosened]]
# Turn both left and right adjustment nuts (13mm) one quarter turn at a time to the desired [[Drive Belt/Tension Check|belt tension]].
#* 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.
# Check that the belt is aligned with belt tension in the right range.
# Re-tighten the left and right jam nuts (13mm).
# Tighten the axle nut (27mm) with the torque wrench (to 75ft-lbs).

;References
: [http://electricmotorcycleforum.com/boards/index.php?topic=3813 Belt alignment discussion]
: [http://electricmotorcycleforum.com/boards/index.php?topic=6921 How to Adjust Your Zero's Belt]
: [http://electricmotorcycleforum.com/boards/index.php?topic=6921.msg56601#msg56601 Notes via Shadow]
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[[Category:Procedure]]
[[Category:Maintenance]]

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