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BDL 3-inch Open Belt Primary Install

Add Some Life to Your Bike
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1. The BDL kit included everything... 
   
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1. The BDL kit included everything necessary to swap out the stock primary.
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2. Stroker started the swap... 
   
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2. Stroker started the swap by draining the primary fluid and removing the outer primary cover. We're never going to need primary fluid again -- one less thing to worry about.
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3. The chain tensioner shoe... 
   
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3. The chain tensioner shoe was nixed next (another part we'll never have to fool with on this bike again), along with the compensating sprocket nut and the clutch. Then the clutch basket, compensating sprocket, and chain were all removed at the same time.
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4. Before the inner primary... 
   
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4. Before the inner primary could be removed, the locktabs on the bolts were bent out of the way...
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5. ...and the pinion gear... 
   
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5. ...and the pinion gear as well.
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6. The inner primary was officially... 
   
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6. The inner primary was officially removed, but there were still a few steps before the new open belt could be installed.
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7. Stroker used a JIMS bearing... 
   
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7. Stroker used a JIMS bearing race puller to remove the inner bearing race on the mainshaft of the transmission.
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8. The motor and transmission... 
   
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8. The motor and transmission mounts were then loosened to insure proper transmission and motor alignment before the backing plate of the BDL primary could be bolted on.
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9. He test fit the backing... 
   
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9. He test fit the backing plate with the motor and trans, shimmed where necessary, then bolted everything down.
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10. The new starter pinion... 
   
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10. The new starter pinion gear assembly was then installed.
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11. He pressed the roll pins... 
   
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11. He pressed the roll pins into the front pulley and stock insert, then used high-strength threadlocker on all the bolts, including the polished alternator cover
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12. Before final installation... 
   
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12. Before final installation of the clutch hub, Stroker greased the splines on the mainshaft in case the clutch hub had to be removed later.
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13. He used a straight edge... 
   
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13. He used a straight edge to check the alignment of the pulleys. Measure and check twice, it never hurts.
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14. Next, the front pulley,... 
   
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14. Next, the front pulley, belt, and clutch hub were installed at the same time.
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15. The clutch hub mainshaft... 
   
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15. The clutch hub mainshaft nut and the front pulley nut were tightened down to H-D specs.
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16. A few fiber and steel... 
   
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16. A few fiber and steel plates were tossed into the clutch hub, then the stack was topped off with the pressure plate with the desired amount of clutch springs. Keep in mind the more springs you use the harder it is to pull the clutch in.
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17. He adjusted the clutc... 
   
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17. He adjusted the clutch...
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18. ...and the clutch cab... 
   
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18. ...and the clutch cable.
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19. A little anti-seize was... 
   
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19. A little anti-seize was applied to the pinion gear shaft bushing.
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20. The starter housing was... 
   
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20. The starter housing was then bolted on.
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21. Stroker used a deep socket... 
   
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21. Stroker used a deep socket wrench to install the hexagonal standoffs that support the outer guard.
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22. With a T-handle hex wrench,... 
   
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22. With a T-handle hex wrench, the hex head button bolts secured the guard to the standoffs.
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23. BDL offers covers for... 
   
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23. BDL offers covers for the pulleys that can be secured with double-sided tape. If you want to go that route, simply stick the tape to the outer edge of the pulleys, and the pulley should stay in place, kind of like a hubcap.
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24. With all the covers in... 
   
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24. With all the covers in place, this is the finished product. We chose the naked look instead -- no pulley covers.
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25. Before.
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26. After. Respect the open... 
   
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26. After. Respect the open beltdrive. Thank you BDL.

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