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Slide jack under the bike, raise the jack enough
to take pressure off of the rear wheel. Unhook brake line from
rear caliper. Remove snap ring from rear axle. Remove axle nut,
remove axle. Move wheel forward to be able to slide the belt off
of the pulley. Remove rear wheel, you may need to raise the jack
to get the wheel out from under the bike.
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Remove the shocks. We welded a 3/8" bolt to a
piece of steel tube to hold the swing arm pivot shaft while
removing the nut on the left side of the bike. Remove the swing
arm pivot shaft and the swing arm.
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Remove three allen head bolts on the
transmission pulley cover, remove the cover and the belt. Have a
friend help set a wheel and tire on the brake side of the rear
end.
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Turn the rear end over on to the wheel that was
just installed. Mark the star plate and a spoke with green tape to
help realign when reinstalling star plate. Remove the five allen
head bolts in the star plate to spokes, lift and remove the star plate
with axle housing and axle as a unit. Install the 1/4" spacer and
pulley. Install 7/16" pulley bolts apply blue loctite and
torque the pulley
bolts. Have friend help hold the center section of the rear end with
a screw driver through a hole in the rotor through one of the holes
in the star plate. Torque the pulley bolts 55 to 65 ft. lbs.
Install spacer on the differential spigot.
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Remove the caliper. Lift up on the pulley and
install the belt on the pulley as shown. The spoke that was marked
with the green tape is at the back side of the rear end. The belt
should be inside of all of the spokes except the front spoke.
Reinstall
caliper and tighten bolts. Slide drive side star plate onto rear
end differential housing, align the star plate with the spoke that
was marked with the green tape. Start
all ½” allen bolts on star plate into spokes, tighten evenly. DO
NOT FORCE BOLTS IN. With rear end bolted together snug, remove the
½” allens one at a time apply blue loctite and reinstall.
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Have a friend help hold the rear end while you
torque the allen bolts to 60 ft. lbs. Both Sides. Install the other
wheel and tire.
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Install the swing arm, the swing arm goes
between the belt with the shock mount on the bottom. The caliper
is on the top and front side of the rear end. Install the bottom
bolt through the swing arm into the star plate on both side first.
Install the bolt in the top mounting hole of the swing arm make
sure to put the washer between the swing arm and the star plate on
both sides. Install the upper shock mounting bracket with hardware
provided. Torque shock mounting bolts to 80 ft. lbs.
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Install shock to upper mounting bracket with
hardware provided, torque shock bolt to 80 ft. lbs. Use bungee
cord to hold shock up while the rear end is rolled under the bike.
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Roll the rear end and swing arm under the bike.
Install swing arm pivot shaft. Remove the bungee cord install
shock in the swing arm shock mount. Install shock bolt provided
and torque to 80 ft. lbs.
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Remove the two upper swing arm mounting bolts so
the rear end will rotate forward. Slide the belt over the
transmission pulley. Reinstall the two upper swing arm mounting
bolts. Have a friend help hold the swing arm pivot shaft while you
torque the nut 120 to 150 ft. lbs. Reinstall pulley cover apply
blue loctite to allen bolts and tighten.
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Install brake line to rear caliper and bled
brakes. Tighten lug nuts and torque 78 to 85 ft. lbs.
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The trike must be sitting
on the ground on its suspension to adjust the belt. We have shown
this with one of the wheels removed for clarity.
Adjust belt tension to factory specs. Tighten jam nut on adjuster
bolts and torque the four rear end mounting bolts to 104 ft. lbs.
Go for a ride. Re-torque lug nuts after 25 miles or 100 mile
maximum.
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