 |
INSTALLATION FOR EVO-3000 |
 |
 |
IMPORTANT UPDATE AND PRODUCT CHANGE BDL items EVO-900 Series 3" Belt Drive with Outboard Support, EVO-3000 Outboard Support Retro Fit Kit and TF-2000 have been changed. We have eliminated the front pulley and engine shaft support and front bearing of the outboard support. The reason for this change was due to the many aftermarket components that come together on a special construction motorcycle, we find that a lot of these components do not allow proper alignment of the entire motorcycle. When using an outboard support that was intended to keep the front engine and rear transmission shafts from moving excessively, improper alignment will cause unusual wear and premature failure of the sealed bearings. By supporting only the rear shaft, which is all that is really needed, we have eliminated any potential problems that mis-alignment may cause. |
|||||
| IT IS RECOMMENDED THAT THE MODIFICATIONS SHOULD BE MADE BY A
QUALIFIED MECHANIC OR MACHINE SHOP. YOU SHOULD NOT TRY TO DRILL
AND TAP THE PULLEYS WHILE ON THE MOTORCYCLE.
ACCURACY IS VERY IMPORTANT FOR PROPER FITMENT 1. Disconnect battery and stabilize motorcycle so that it will not fall while working. 2. Remove dome covers from pulleys and remove front pulley and rear clutch basket assembly. |
|||||
 |
A-EVO-3000SP Support plate B-EVO-3000RC Rear pulley cover C-EVO-3000FC Front pulley cover D-EVO-3000BC Bearing covers (2) E-EVO-3000SO Standoffs (4) F-EVO-3000SB Sealed bearings (2) G-EVO-3000PP Pressure plate Hardware: 3-5/16-18 x 3 Sockethead cap screw 6-10-24 x 3/8 Flathead socket cap screw 4-5/16-18 x 1-1/4 Sockethead cup point set screw 4-5/16-18 x 1-1/4 Buttonhead socket cap screw 4-10-24 x 1/4 Buttonhead socket cap screw |
||||
| 3. Remove any standard or offset insert from front pulley. Firmly mount the front pulley on a drill press or mill, then on the back side of the pulley, place aluminum template on the pulley and align large hole with one of the large exsisting insert holes. You may place a 5/16 bolt through the hole for alignment. Using a “F” (.257) drill bit, drill all the way through the pulley, then tap the 3 holes with a 5/16-18 bottom tap. |
|
||||
| 4. Remove the shoulder bolts, springs, pressure plate and clutch pack from rear clutch basket. Firmly mount the rear clutch basket on a drill press or mill, then using the new rear pulley cover as a template, provided with the kit, align and prespot the 6 holes on the flange area of the clutch basket with a #7 .201” drill bit then using a #25 .1495 drill bit, drill the 6 holes all the way through the flange area. Tap the 6 holes with a 10-24 bottom tap. | |||||
 |
|
||||
 |
|
||||
|
|
||||
| 5. Re-assemble pulleys using the new pressure plate supplied with kit and re-install belt drive onto motorcycle as per BDL original instructions. Be sure to re-adjust your clutch at this time. |
|
||||
| 6. Install front and rear pulley covers using the supplied hardware ( it is recommended that you use blue loctite) |
|
||||
|
|
||||
| 7. Install the 4 standoffs supplied using the new set screws. |
|
||||
| 8. Install the outboard support, checking carefully for fitment, install the new 1-1/4” long buttonhead screws. | |||||
|
|
||||
|
|
||||
