HOME OF PRIMO BELT DRIVES QUALITY & PERFORMANCE SINCE 1973 BRUTE FORCE TM. Belt Drive INSTALLATION INSTRUCTIONS

Transcription

1 HOME OF PRIMO BELT DRIVES QUALITY & PERFORMANCE SINCE 1973 BRUTE FORCE TM Belt Drive INSTALLATION INSTRUCTIONS 3-1/2 WIDE / 14mm BELT FITS EVO & TWIN CAM SOFTAIL PRIMO BRUTE FORCE TM BELT DRIVE (pictured with OPTIONAL LED taillight/license plate assembly) ** SAFETY NOTE: CARBON FIBER GUARDS MUST BE INSTALLED PRIOR TO STARTING Use of the word Harley-Davidson, various motorcycle model names & designations & OEM part numbers are for end-user reference or application information only. No affiliation between Rivera Primo Inc. & The Harley-Davidson Motor Company exists or is implied by the use of said information. Rivera Engineering, Pro-Clutch, Primo, and Primo Belt Drives are registered trademarks of Rivera Primo Inc. Unauthorized use is prohibited by law. la Whittier Blvd, Whittier, CA Tel: (562) FAX: (562)

2 IMPORTANT! ** Prior to starting this installation, disconnect and remove the battery. Secure the motorcycle so it will not fall and so you have complete unobstructed access to the primary drive side of the motorcycle. ** Use blue threadlock on all bolt threads except starter jackshaft, & clutch hub studs. ** Use anti-seize on the clutch hub studs, and rear pulley bearing support shaft hubcap. ** Remove all ORIGINAL PRIMARY DRIVE components including inner & outer primary covers. Remove the factory INNER PRIMARY BEARING RACE on the transmission main shaft. Check the sprocket shaft and the transmission main shaft for leaky seals and replace the seals as needed at this time STEP 1 : Install the double ended starter extension into the starter. Do this prior to installing the rear motor plate section. Just the extension portion, not the complete jackshaft assembly. STEP 2 : Install the rear motor plate section on the transmission using the supplied FOUR 5/16-18 X 1 1/4 bolts. Do not tighten the bolts completely at this time. The sealed bearing in the motor plate is a slip-fit on the transmission main shaft. STEP 3 : Install the front motor plate section using the two 5/16-18X 1 1/4 inch bolts front, and two 5/16-18 X 1 1/2 rear. Start the 5/16-18 X 1 1/4 center bolts w 5/16 washers, and motor plate to engine case bolts initially. Ensure that the motor plates are properly seated and aligned. Tighten all bolts equally... TORQUE TO 29 FOOT POUNDS. STEP 4 : Install the starter jackshaft assembly (with pinion gear) after installation of the rear motor plate. Be sure to seat the thrust washer in the groove and bend the lock tab over against the bolt head. STEP 4A : Air gap between ring gear and pinion gear Measuring the air gap Install the rear pulley (clutch basket) and hand tighten the clutch hub nut making sure it is snug. Note that this nut is left-hand thread. At this time it is important to check the air gap between the back side of the starter ring gear and the pinion gear. Recommended gap should be.075 to.125. Use an 1/8 Allen wrench to measure the gap. Just slip the short end of the wrench between the ring gear & the pinion gear. If it fits, great. If there is too much gap, the jackshaft assembly should be shimmed to reduce the gap to the spec above (order # shim kit). 2

3 STEP 5 : Install the front pulley bearing retainer SPACER and the front pulley insert by dropping the spacer into the front pulley, while holding the pulley insert against the back of the front pulley. Align the holes and attach using the using the five 5/16-18 X 1 1/4 bolts. Use RED threadlock here. TORQUE THESE BOLTS TO 29 FOOT POUNDS. STEP 6 : Install the belt, the front pulley and the rear pulley together, sliding the pulleys onto the motor sprocket shaft and transmission main shaft simultaneously. STEP 7 : Install and tighten the clutch hub nut on the transmission main shaft (left hand threads) and the motor nut on the sprocket shaft (right hand threads) per OEM specs. TORQUE CLUTCH HUB NUT TO FOOT POUNDS. TORQUE ENGINE NUT TO FOOT POUNDS. 3

4 STEP 8 : Install the clutch pack into the rear pulley/clutch basket. The.120 steel plate goes in first, followed by a friction plate, then a steel plate, alternating until all clutch plates are installed. STEP 9 : ANTI-SEIZE Install the pressure plate, diaphragm clutch spring and spring retainer using the four shouldered nuts (generously apply anti-seize on the clutch hub stud threads). Make sure you install the lock clips under nuts. Tighten the nuts equally until the nuts bottom. THEN TIGHTEN TO 30 INCH POUNDS, NOT FOOT LBS. Bend tabs on the lock clips over against nuts. STEP 10 : Install the starter support housing using the two 5/16-18 X 3/4" bolts provided. TORQUE THESE BOLTS TO 29 FOOT POUNDS. 4

5 STEP 11 : Using blue threadlock, install the four aluminum stand-offs onto the motor plate assembly. The stand-off with the machined radius on the bottom goes in the front motor plate section just to the rear of the front pulley. If your kit came with 5/16 STAND-OFF STUDS, TORQUE THEM TO 29 FOOT POUNDS. If your kit came with 3/8 STAND-OFF STUDS, TORQUE THEM TO 47 FOOT POUNDS MOUNTED STAND-OFFS two long two long STEP 12 : Install the rear pulley bearing retainer (flying saucer shaped) onto the clutch basket assembly with the six 1/4--20 X 1/2 bolts provided. Use blue threadlock here. TORQUE TO 14 FOOT POUNDS STEP 13 : Install the front pulley bearing carrier in the front pulley with the five 5/16-18 X 3/4" bolts supplied. Use blue threadlock. TORQUE TO 29 FOOT POUNDS. 5

6 STEP 14 : Install the INNER OUTBOARD BEARING SUPPORT PLATE with the "bearing support shaft" into the front pulley and install the bottom-front bearing STAND-OFF (part # , long with 2 flats & four tapped holes) between the motor plate and the front bearing support. This STAND-OFF has threaded holes to secure the front of the upper and lower carbon fiber belt guards. Do not tighten this STAND-OFF at this time. It must be rotated to align the holes when installing and securing the upper and lower carbon fiber belt guards. STEP 15 : Install the OUTER OUTBOARD BEARING SUPPORT section onto the clutch basket assembly. Use the short stand-off (.747 ) at the top and the long STAND-OFF with one flat with two tapped bolt holes (secures the rear of the lower belt guard) on the bottom to attach the outer bearing support to the rear motor plate section. Install the 5/16-18 X 2 bolt thru the.747 STAND-OFF (TOP REAR), and 5/16-18 x 5 1/2 bolt through the bottom rear STAND-OFF (use blue thread lock). Use the 5/16-18 X 1 1/4 bolts to secure the front of the outer bearing support to the STAND-OFFS already installed on the rear motor plate. Tighten all the bolts equally. TORQUE TO 29 FOOT POUNDS. Secure the center of the outer OUTBOARD BEARING SUPPORT to the center STAND-OFFS with the two 5/16-18 X 1 1/4 bolts provided & TORQUE TO 29 FOOT POUNDS. ANTI-SEIZE MUST BE APPLIED TO THE THREADS OF THE SPIN-ON BEARING SUPPORT-SHAFT HUB-CAP..747 STAND-OFF APPLY ANTI-SEIZE TO THESE THREADS STAND-OFF with one flat & two holes STEP 16 : Install the "Brute Force" NAME PLATE onto the bearing support assembly using the X 3/8 socket flat cap bolt. Use one drop of blue threadlock & snug the bolt. 6

7 STEP 17 : Carefully install the lower carbon fiber belt guard using the 10/32 x 3/8 bolts & washers provided. Use a drop of blue threadlock and snug the bolts. The shiny surface of the carbon fiber belt guard is easily scratched. Avoid rough handling of this surface. Rotate the lower-rear and lower front STAND-OFFs to line up with the holes on the lower Carbon Fiber belt guard. Start the bolts using blue threadlock. STEP 18 : Install the upper carbon fiber belt guard using the 10/32 x 3/8 bolts & #10 washers provided. Use a drop of blue threadlock and snug the bolts. The shiny surface of the carbon fiber belt guard is easily scratched. Avoid rough handling of this surface. Rotate the lower-front STAND-OFF to line up with the holes on the upper Carbon Fiber belt guard. After both the upper & lower guards have been installed tighten the lower STAND-OFF bolt using blue threadlock. TORQUE TO 29 FOOT POUNDS. optional license plate bracket with LED taillight Billet aluminum chromed straight license plate bracket for Brute Force belt drives (Retangular Light) 7

8 CLUTCH ASSEMBLY - BRUTE FORCE TM / 3-1/2 WIDE / 14 mm BELT IMPORTANT INFORMATION DO NOT OPERATE this or any other Rivera Primo Inc. open primary belt drive without the proper safety guard or belt cover in place. Install the supplied guard or suitable other guards and/or belt covers available from Rivera Primo Inc. prior to starting the motorcycle. ADEQUATE GROUND CLEARANCE is extremely important, especially when turning to the left. Once installed, make certain the belt drive assembly does not in any way interfere with this turning geometry. Should there appear to be a problem, correct it immediately so as to provide adequate & safe ground clearance. DO NOT OPERATE the motorcycle until this is done! LIMITED WARRANTY: All pulleys are warranted to be free from defects in material and workmanship under normal use for a period of one year from actual date of purchase. Seller s liability shall be limited to repair or replacement of any materials found to be defective, free of charge at it s plant or authorized service depots, of specific manufactures components. It is further warranted that products that were designed for a specific purpose, shall perform for that purpose when installed exactly as defined in the Installation Instructions accompanying the unit. In no event shall Rivera Primo Inc. or seller be liable for consequential or special damages asserted to be attributed to malfunction of our product, for any reason including, but not limited to, damage asserted to be from improper installation of our purchased Primary Belt Drive components. This warranty shall not apply to any products which have been subjected to abuse, neglect or accident, nor shall it apply to any product which has been repaired or modified by any person not specifically authorized in writing by the manufacturer. THERE IS NO WARRANTY ON BELTS. Due to the differing conditions and circumstances under which all belts are installed and used, Gates Rubber Company will not warranty any belt for length of service. Regardless of belt type, keeping your system free of debris and other objects is most important. Remember too, improper handling of the belt can shorten service life. Do not crimp the belt. Do not twist the belt. Do not pry the belt onto the application. If you re shipping or storing, try to eliminate forward and back-bending of the belt. LIMITATION OF LIABILITY: THERE ARE NO IMPLIED WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE OF ANY SHIP- MENT AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY AND FITNESS EXCEPT THAT THE MATERIAL SOLD HEREUNDER SHALL BE OF SELLER S STANDARD QUALITY, and buyer assumes all risk and liability for all loss, damage or injury to person or property resulting from the use of said material in manufacturing processes or in combination with other substances, or otherwise. Except as otherwise provided herein quality shall be in accordance with seller s specifications. Final determination of the suitability of the material for the use contemplated by buyer is the sole responsibility of buyer, and seller shall have no responsibility in connection with such suitability. RIVERA PRIMO Inc Whittier Blvd, WHITTIER, CA (562) FAX (562) info1@riveraprimoinc.com 8