New BDL EVO-3000 Installation
Perfect Support Belt Drive System
Text by Wrench, photos by Bandit and mechanical assistance from Mailman

BDL

20 new bdl sys. 
in box
We're going to take you through this New BDL installation from start to finish. Generally belt drive installations are straight forward. There's a couple of key issues: The inner primary is your guide to a proper running, aligned belt drive. If it's square to the engine and tranny, all else is golden. This new drive EVO-3000 helps guarantee that your pulleys are aligned through the outer bearings and plate.

1 primary 
before shot
Here's Roger's Softail just before we kicked into gear.

The only other element that needs scrutiny is the starter pinion shaft and gears. With a little care and measuring, your starter will work effortlessly for years to come. Watch the installation closely.

Let's get to work: This application was chosen for a near-stock Evo Softail with no offset. Roger won the Free Bikernet Door Prize Giveaway that we post weekly. BDL has offset insert kits for their front pulleys from 1/4-inch to 2 inches.

2 remove outer 
primary

3 teflon chain 
tentioner
Check the grease in the chain case.

4 comensator 
sprocket

5 breaking 
comp. sprocket
Note how we jammed the screwdrive handle into the primary chain.

6 compensator 
sprocket apart
This compensator sprocket was backed with a heavy Fisher balancing system.

7 removing 
chain tentioner nut
The chain tensioner must go before the primary drive can be removed.

8 clutch 
pushrod adj. removed
An internal snap ring holds the clutch adjuster plate in place. It must be removed before we could reach the clutch nut.

9 remove 
clutch nut
Remember the 1/3/16 socket is turning a left handed nut.

10 clutch nut
The lefty clutch nut removed.

12 engine 
sprocket shim
We saved this shim for use with BDL pulley spacing.

We started by removing the primary cover on Roger's home-built custom Softail. For some reason, instead of oil Roger packed his inner primary with grease. The chain was loose as hell. It took a 1 1/2-inch socket to remove the compensator nut. We used the handle of an old screwdriver to jam the chain. Mailman grabbed a 9/16 socket and removed the chain adjuster nut, while I dug out a 1 3/16 socket for the clutch basket, which is left handed.

13 removing 
battery cable
It's always a good idea to disconnect the battery.

14 starter gear 
removal

15 removing 
starter gear bolt

We stopped for a minute and removed his custom embroidered seat and the ground wire from the battery to the frame. You don't want to touch that starter drive with the battery connected--it will engage.

11 primary 
drive removed

16 mailman 
removing starter
Mailman jumped to the right side of the bike with a long extention and an Allen socket to remove the two bolts that hold the starter in place.

17 starter 
bolt
Here's one of the starter installation bolts.

We removed the driveline as one piece and set the greasy bastard aside. With a screwdriver or wedge we bent the tab on the starter drive gear and with a 5/16 socket removed the long bolt from the starter jack shaft. We set this stuff aside in case we might need it for the installation, although the BDL kit comes with a complete starter pinion shaft and gear.

18 inner 
primary bolts
All the bolts left over from the stock inner primary.

19 starter shaft 
and parts
Here's his starter pinion shaft parts up to the coupler for the Compu-Fire starter.

Here's the catch. If you're not running a stock starter, you may need some versatility when it comes to the installation. We did since Roger ran a Compu-Fire starter. Next, we removed the starter Allens from the right side and set them on the lift. The starter didn't need to be removed or disconnected, just backed out.

Note from a reader: First, the BDL installation guide is GREAT! There is, however, one VERY important part missing and I hope you can add a notation to the web.

After successfully installing my BDL, I notice a few drip of oil after every ride. Nothing major at all, but annoying. After pulling the drive train several time, I finally called S&S and learned that the Sprocket Shaft Seal needs to be installed the opposite direct as with wet primaries.

The Harley Part number is 12026B. It's an easy install, but a real pain to pull the entire primary, so this would be a very good tip to include EARLY in the guide.


Hope this will help anyone else installing an Open Primary...

On to Page 2...

Back to Belt Drives LTD on Bikernet...








ENTER THE CANTINA


Search Bikernet.com using

Google




Bikernet.com - Est. January, 1996

FREE DEPARTMENTS

  • Home
  • The Bikernet Blog
  • The Bikernet Blog RSS Feed
  • Bikernet on Twitter
  • Bikernet's Twitter RSS Feed
  • Bike Features
  • Bandit's Cantina
  • Bars And Hangouts
  • Bikernet Biz
  • Bikernet Studios
  • Bikernet Thursday News
  • Bikers Rights News
  • Bonneville 2006 Effort
  • Bonneville 2007 Effort
  • Buell Report
  • Events Calendar
  • Event Coverage
  • Freedom Film
  • Free Contest
  • King Report
  • Knucklebusters
  • Memorials - Fallen Bretheren
  • Motorcycle Web Links
  • Movies & Music Reviews
  • Nick the Dick
  • Road Tests
  • Shop Listings
  • Special Reports
  • The Sportster Reports
  • Techs & Bike Builds
  • Two Wheeled Tales
  • Virtual Classifieds
  • Your Shot Forum
  • SPONSORS

  • Accurate-Engineering
  • Accident?
  • American Motorcycle Specialties
  • AVON Tyres
  • Baker Drivetrain
  • Belt Drives LTD.
  • Big Dog Motorcycles
  • Big Twin West
  • Biker's Choice
  • Brass Balls Bobbers
  • Compu-Fire
  • Custom Chrome
  • Custom Powder Coating
  • D&D Exhaust
  • Easyriders Events
  • Hot Leathers
  • Jims USA
  • K & G Cycles
  • Keyboard Motorcycle Shipping
  • Law Offices of Richard M. Lester
  • Le Pera Seats
  • Lucky Devil Metal Works
  • Lil Joes Leather
  • Metric Thunder
  • Motorcycle Rights Foundation
  • S&S Cycle
  • Saddlemen
  • Saxon Motorcycles
  • Spectro Oils
  • Streetwalker Exhaust
  • Sucker Punch Sally's
  • Wire Plus
  • Zipper's Performance / Thundermax
  • CONTACT INFORMATION
    Bikernet.com
    200 Broad Ave, Wilmington, CA 90744
    Phone (310) 830-0630
    E-Mail Bandit       E-Mail Sin Wu
    Send this page to (e-mail address):
    Your Name:
    Click for Bikernet Homepage Bandit's Bikernet is a registered trademark of 5 Ball, Inc.
    © 5 Ball, Inc. 1996 - 2009. All Rights Reserved.