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INSTALLATION FOR BOLT IN BELT DRIVES (1970-1983 MODELS)

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1. Be sure to read the Warranty, Introduction, belt tracking and starter gear problems, alignment procedure and disconnect battery.

2. Install front and rear pulleys and check for clearance. At this time you should determine if the front pulley will need shimming or not depending on how the pulleys align with each other. Remove pulleys and make any modifications if necessary.
(Note: On early FXR & Shovelhead, you may have to grind bottom of starter fork.


3. On Shovelhead models, shut off primary oil and re-plumb lines.

4. Grease support bearing.

5. Make sure motor and transmission shafts are aligned and square with each other.
6. If front pulley shimming was necessary be sure that the shims are in place, now install rear pulley, belt and front pulley at the same time.
Press stock bearing out of the primary
Engine shaft spline should not protrude from pulley.
When using any of BDL's inserts with special nut, please note that the nut is counter-bored to cover the splines should they protrude.
COVERING THE SPLINE IS VERY IMPORTANT

Rotate the motor by hand using a socket wrench, the belt should track straight and away from motor but not off of the front pulley. Be sure to red loctite front engine nut and torque to HD specifications. (Electric impact is preferred).

7. Apply loctite and install and tighten stock HD main shaft nut with seal, using HD specifications.
Rotate motor by hand using a socket wrench, and check to see how belt tracks
8. Install clutch pack, refer to schematic (below) spline steel first, 1/2 sided friction plate with fiber facing out, then alternate steel and two sided fiber plates ending with the other 1/2 sided friction plate with fiber facing in. Install pressure plate, springs and shoulder bolts. To install shoulder bolts apply red loctite to a bolt and install it one turn, go on to the next bolt with same procedure until all 6 bolts are in place, then tighten them all the way down until they bottom out. There is no adjustment to the spring pressure, this is all pre-determined with the length of the shoulder bolt and exact dimensions of our pressure plate.

9. Install stock HD adjusting screw and adjust clutch with at least 1/2" lever free play to allow for clutch growth when running. Tighten adjusting screw nut when adjustment is complete. (We do not supply a clutch adjusting rod with Shovelhead kits you must use the stock HD adjusting rod).

10. Install outer primary cover with gasket and tighten all bolts to HD specifications.

11. Listen to be sure starter pinion gear engages before motor turns over. Refer to starter gear problems.