I need help - 2003 1000ds engine - belt drive pulley clearance issue

[Speeddog]

Re-use, with blue loctite.
The torque spec is *very* tight

Do you have the pulley-holding tool?

[Duck-Stew]

Re-use, with blue loctite.
The torque spec is *very* tight

Do you have the pulley-holding tool?

If not, try to borrow one from the local shop.  So long as you return it un-busted...and with a 6-pack, some shops will loan tools if you're good w/the mgr.

[mitt]

I made the tools 3 years ago...






I tried to post them earlier, but they are not showing up.

mitt

[krista]

When degreeing cams, the difference between a new one and a used one will shift the camshaft 2 degrees in the keyway. New nuts are like $8 each and we have (or had?) plenty. I don't reuse them... now. But I did before that. If you read that other thread about belts, you'll see where I blather on about what works versus "best practice". If you get the nut to 50 ft-lb, it'll be fine.

Chris

[Speeddog]

'09 Hyper 1100

Pulley flange diameter - 2.378"

[phildo]

I have an 03 and was able to change belts without removeing pully, but it was close. A few thousands less clearance and I don't think they would have slipped past the pully lip. I wonder if some of the early DS bikes have just enough variation to allow some belts to come off and others not? How much do you guys think the belts vary in thickness?

[Raux]

did the belt son the 696 today and i sorta saw the same problem. had to flatten it as much as possible and work the edge not to get caught on the engine case or flange going in and out.

i was like "this can't be right"

[vaclav]

If we are talking a few thousandths, would it be so wrong to Dremel a few thou off the end cap of the pulley just at that one spot?

[mitt]

'09 Hyper 1100

Pulley flange diameter - 2.378"

I had the damn pulley off this weekend, and I forgot to measure.  I went ahead and tried to measure it on the bike, and the best I number I can repeatable come up with is 2.3815" - so it is possible it is a little bigger.  None of my measurements were below 2.38.

There was no way I was getting the belts off with the pulley on - so my memory was right.  I did notice some material removed from the case under the pulley, but it didn't seem far enough out to help with getting past the pulley lip.

What Hz is everyone adjust 1000ds's too?  My manual says 142, but I think that is a little high if memory serves.  The laptop + mic + audacity works pretty sweet though.

I went ahead and reused the nut w/ some blue loctite and took it to 72Nm like the manual says.


mitt

[ducpainter]

http://ducatimonsterforum.org/index.php?topic=17039.msg300058#msg300058

[Speeddog]

Got an '06 DS here in the shop.

Didn't notice it before (or did, and forgot  )

There are 2 different pulleys.

A 'one piece' looking part, like HeMan's pic shows.
And a 2-piece unit, like Mitt's, where the flange is swaged on.

Old belts needed a tiny bit of a tug to get past the flange.

I'll see what the new belts say about install....