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Instruction timing-belt
Ideally support the bike with a paddock stand,
axle stands or what have you. Tank off, spark
plug out, cam belt cover off, rocker box covers
off. Now remove the three screws from the
alternator cover, you will probably not be able to
pull it off because it is a tight fit so tap it gently
around the edge with a hide or nylon hammer,
now a little bit of wiggling and it should come
off. DO NOT lever it with a screwdriver you
will easily damage the machined faces.
The stator is fixed to the inside of the cover so it
is quite heavy, tie it to the bike with a bit of
string to stop it hanging on the wires. Put the
bike in 5th gear and stand on the back brake, this
should lock the crank well enough for you to
remove the bolt from the centre of the rotor.
Screw the protector pad into this thread then
screw on the puller. Now rotate the engine (by
the back wheel) until the mark on the rotor lines
up with the mark on the crankcase (it is at abou
t one o’clock). The marks on the cam pulley wheels
should be in line with the horizontal break in the
housing (i.e. the inlet mark at 3 o’clock and the
exhaust at 9 o’clock). If they are not rotate the
engine 360 degrees and check again. Now it is at
TDC on the firing stroke, hold the puller body
with a spanner to stop it moving and tighten the
puller bolt to remove the rotor.
When you remove the rotor a woodruff key and
three large washers will fall out. Remove the nut
and spring washer from the belt tensioner then
pull the tensioner wheel off, now you can remove
the belt. When you fit the new belt it is easy to be
one tooth out because of the slack, so put the belt
on the crankshaft and work from the front keeping
the belt tight as you fit it first to the exhaust then
the inlet. Use your finger in place of the tensioner
and check that the pulley marks are in the correct
place. If OK fit the tensioner and torque the nut
to 28-30 Nm.
The tensioner spring should have correctly set the
belt tension. Be very careful with the new belt
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