| Author | Message | ||
     Blackbichgsx |
Below is the 'How-To' for converting from the horrible 2003 belt to the rocking 2004+ belt. I bought most of the items, but the belt and bolts used to save some cash. This does not follow the Service Manual exactly, but does use there torque specs. HOW TO - 03 to 04+ Belt Conversion Parts list as posted by Court on the XBoard: 1. Front sprocket 40288-95 (27 tooth) $56.00 2. Front Sprocket Cover G0555.1AA $37.95 * 3. Stone Deflector N/A Discard/Remove 4. Upper Belt Guard M0570.1AA $33.25 * 5. Lower Belt Guard M0560.1AA $46.60 * 6. Inner Belt guard Discard/Remove 7. Rear Sprocket G0400.1AA (65 tooth) $117.00 8. Rear Sprocket Bolts AA0609.11CXZB (Qty 6) $2.75 9. Belt G0500.1AAA $152.00 10. Idler Pulley Assembly G0604.1AA (can't buy bracket separate) $91.55 11. Rear Master Cylinder H0205.1AA (moves brake line away from belt) $57.80 12. Rear Brake Line H1522.1AA (w/banjo bolts and crush washers) 2003 line will be short with 2004 MC $32.50 13. Swingarm Brace Bolt Short AA0507.2CZB (three required for job) need to buy one $1.70 14. Swingarm Brace Bolt Long AA0522.2CZB (one required) Delete/Discard Replace with short from above Total, plus TTL, $622.81 - less the BWB sponsors discount of 10%? $566.19 ? Notes: 1. Items with (*) after are also available in Carbon Fiber from Buell for some $$.$$ 2. 65/27 = 2.407 drive ration same as 2003, no speedometer, or calibration change needed. Start by getting the rear of the bike supported in some form. I did this my own way, so it may not follow the repair manual exactly, but it worked for me. REMOVAL PROCESS Remove the two bolts that hold the brake caliper to the swing arm Move the caliper off to the side of the swing arm Rear Brake Caliper Bolts Remove all the bolts you can access on the belt guard Loosen the axle pinch bolt under the swing arm Remove the rear axle Guard & Wheel Remove the chin fairing bolts on the right side Remove the front sprocket guard bolts Remove the front sprocket guard Front Sprocket Guard Break the rear master cylinder banjo bolt loose Master Cylinder Banjo Remove the three bolts that hold on the rear set Rear Set Remove the two bolts that hold the brake master cylinder on the rear set Remove the cotter pin from the brake lever Rear Master Cylinder Remove the two bolts holding on the idler pulley Remove the inner belt guard Before Removal Idler and Inner Guard Removed Remove the remaining bolts that hold on the belt guard Belt Guard in Swing Remove the three bolts remaining that hold the top of the swing arm Jog, twist and fight to get the belt and guard off the swing arm Swing Arm Apart My girlfriends dog stopped by to help and interrupt Dog (Codie) Remove the two bolts that hold the front sprocket lock on the sprocket I used a socket to lock the sprocket from moving Sprocket Jammed Sprocket Lock Removed Now comes the hardest part of the whole thing (1 7/8 socket required) Remove the sprocket nut I used a socket to lock the sprocket from moving. Then I put a 3/4-1/2 adapter on a 1/2 breaker bar, with a jack handle slid on. Remember this nut is reverse threaded so you have to turn to the right (clockwise). Sprocket Jammed Pry bar & Jack Handle Remove the 6 bolts holding the sprocket to the wheel Wheel Sprocket INSTALL PROCESS Place the 04+ Sprocket on the wheel and torque the 6 bolts to 35-37 ft-lbs Wheel Sprocket Slide 04+ front sprocket onto output shaft of the transmission Front Sprocket Distribute a little 20W-50 on the back of the front sprocket nut Oil on Nut Put a couple drops of red Loctite onto the threads of the nut Loctite on Nut Install nut and torque to 50 ft-lbs (socket used like removal) Torque Sprocket Install nut lock plate on the front sprocket (socket used like removal) Lock Plate Remove the seat to get access to the rear master cylinder resivour Seat Removal Remove the reservoir hose from the master cylinder and allow to drain (I used a can) Then remove the lid to the reservoir to get the remaining fluid out Remove Hose Remove the 03 master cylinder from the banjo bolt 03 Cylinder Install the 04+ master cylinder banjo bolt and reservoir hose Slip 04+ belt into place (don't need the inner belt guard) 04+ Cylinder Installed Install the rear master cylinder to the rear set with the two bolts and pin Rear Set Bolt up rear piece of the swing arm into place (uses new bolt) Swing Arm Support Get wheel into position and slide axle into place with only 2 to 3 threads engaged. Rear Wheel Place the idler pulley into place and torque to 33-35 ft-lbs Idler Pulley Install Tighten rear axle to 48-52 ft-lbs Tighten pinch bolt to 40-45 ft-lbs Pinch Bolt Install rear caliper and tighten bolts to 24-26 ft-lbs Rear Caliper Install the 04+ front sprocket cover with the old 3 bolts Front Sprocket Remove the rear swing arm brace and install the 04+ upper belt guard Upper Belt Guard Reinstall the swing arm brace with belt guard Swing Arm Install Install the 3 bolts that hold the rear set into place Rear Set Tighten the banjo bolt to the rear master cylinder Rear Banjo Tighten Install the bolts from the front chin fairing Chin Fairing Fill the rear brake reservoir with DOT 4 fluid Rear Brake Fill Squeeze the tube to the master cylinder to get some air out Tube Squeeze Bleed the brakes Install the seat Rear Caliper Install the 04+ lower belt guard Lower Belt Guard Admire the work you just did and get ready to ride DONE! (Message edited by blackbichGSX on May 27, 2008) (Message edited by blackbichGSX on May 27, 2008) (Message edited by blackbichGSX on May 28, 2008) | ||
| U4euh |
Just wanted to say thanks, you saved my ass today with the pictures!! | ||
| Half_buell |
The local HD says I need the1AAG,not the1AAE belt does anyone know for sure? | ||
| Al_lighton |
Either will work, but the AAG is the superceding belt that has been made tougher yet. They're the same dimensionally. Al | ||
| Blackbichgsx |
No problem, that's why I did this. I was in your shoes and confused with no sure direction. As for the belt, don't listen to HD, get the revised version. Most of the time the dealers have no idea what they are talking about, at least from my experience. Books can only tell you so much. | ||
| Blackbichgsx |
EDIT: I just realized today that I needed to add the final torque of the front sprocket nut. The following needs to be changed: Install nut and torque to initial 50 ft-lbs (socket used like removal) Final torque by turning 30-45 degrees} |
