BDL (Belt Drives Ltd.) is a leading manufacturer of belt drive systems for high-performance motorcycles. Their belt drive systems are engineered for durability, precision, and compatibility with a variety of engine configurations. However, the successful installation of BDL belt drives requires strict adherence to technical specifications and installation protocols. This article provides a comprehensive overview of BDL belt drive installation guidelines based on the manufacturer’s instructions and technical documentation.
Installation Overview
BDL belt drives must be installed by a qualified mechanic due to the complexity of the system and the precision required for proper alignment and operation. The installation process includes several critical steps that, if not followed exactly, can lead to premature component failure or void the manufacturer’s warranty. The manufacturer emphasizes that improper installation can result in damage to the belt, starter gear, or other drivetrain components.
Prerequisites for Installation
Before beginning the installation process, several preparatory steps must be completed:
Qualified Installation: The installation must be carried out by a certified technician or experienced mechanic. The manufacturer explicitly states that failure to follow installation instructions will void the warranty and the company’s liability.
Use of Stock OEM Components: BDL recommends using stock OEM parts for installation. The use of aftermarket components may necessitate additional modifications and could lead to alignment or starter gear issues.
Registration: A registration card must be completed and returned to the manufacturer promptly. Failure to do so will result in the warranty being voided.
Vehicle Preparation: The battery must be disconnected, and spark plugs removed to prevent accidental starting during the installation process. The motorcycle must be supported securely to avoid falling during the procedure.
Component Inspection: A new BDL belt drive must be inspected to ensure it is free of defects and fits properly. If the installation is a replacement, the existing primary drive must be removed. For new builds, the user should proceed to the appropriate installation page based on the bike’s configuration.
Alignment and Handling: The belt must never be pinched, crimped, twisted, or bent in any way. These actions can break down the internal cords, leading to premature failure. Proper alignment is essential, and the manufacturer provides specific alignment procedures that must be followed exactly.
Belt Drive Components and Installation Steps
BDL belt drive kits include several components that must be assembled in the correct order to ensure optimal performance and longevity:
Pressure Plate (DPP-100): This component is responsible for applying pressure to the clutch plate assembly.
Diaphragm Spring (DES-100): A black diaphragm is used for stock applications, while a copper-colored diaphragm provides a stronger spring pressure. For high-performance motorcycles, both diaphragm springs can be used.
Spring Collar (DCS-100): This collar is placed over the diaphragm spring and must be installed with the tapered side facing the spring.
Shoulder Bolts (ESB-1000): Four 1-inch shoulder bolts are included in the kit. These are critical for securing the pressure plate and must be installed with 3/8-inch AN washers for added stability.
Clutch Pushrod Adjuster: A new pushrod adjuster with two O-rings is included. The O-rings must be oiled before installation to ensure smooth operation.
Hub Nut (1 1/8-inch): The hub nut is used to secure the clutch assembly and must be tightened according to the manufacturer’s specifications.
Step-by-Step Installation Procedure
Remove Old Pressure Plate: The first step in the installation process is to remove the existing pressure plate from the clutch assembly.
Apply Thread Locker: Blue thread locker must be applied to the four-hole pattern in the BDL clutch hub to ensure secure fastening.
Install Adjusting Screw: The adjusting screw must be installed from the backside of the pressure plate to avoid damaging the O-rings. A jam nut is loosely installed onto the adjusting screw, and the adjuster O-rings must be oiled.
Install Diaphragm Spring and Spring Collar: The diaphragm spring is installed first, followed by the spring collar. The spring collar must be oriented with the tapered side facing the spring.
Lubricate Clutch Components: The pocket in the clutch side of the adjusting screw must be lubricated with gear oil or assembly lube before installation.
Secure Components: The pressure plate and shoulder bolts are installed and tightened according to the manufacturer’s specifications. The pushrod must be positioned correctly to avoid bottoming out and damaging the throw-out bearing.
Customization and Performance Enhancements
BDL offers several customization options for riders and builders looking to fine-tune their clutch systems for specific performance goals. The choice between diaphragm and coil spring applications allows users to adjust the clutch pull and pressure to suit their engine configuration.
Diaphragm vs. Coil Spring Applications
For stock applications, a single black diaphragm is typically sufficient. However, for motorcycles with higher performance requirements, a copper-colored diaphragm can be used to increase spring pressure. For even greater pressure, both diaphragms can be used in conjunction.
Coil spring applications provide an alternative for riders who prefer a lighter pull at the clutch lever while maintaining high-pressure engagement at higher speeds. BDL’s ball bearing clutches are designed to reduce tension at the lever while increasing plate pressure during high-speed operation.
Spring Configuration
The number of springs used in the clutch assembly can also be adjusted to meet performance needs. For stock applications, as few as four springs may be used. High-performance motorcycles typically require eight to twelve springs, depending on the specific engine build. Users are encouraged to start with six springs and adjust up or down based on their application.
Washers can be added under the head of the shoulder bolts to increase spring pressure further. This allows for fine-tuning of the clutch engagement point and overall feel.
Compatibility and Application Notes
BDL belt drive systems are compatible with a wide range of motorcycle engines and configurations. However, certain modifications may be required for non-stock applications. The manufacturer notes that alignment is a critical factor in the performance and longevity of the belt drive system.
Belt Tracking and Alignment
Proper belt tracking is essential to prevent premature wear and failure. The belt must be aligned so that it runs straight along the grooves of the pulleys. If the belt begins to drift to one side, it can cause uneven wear, reduced power transfer, and potential belt breakage.
The manufacturer provides specific alignment procedures that must be followed exactly. These procedures include checking the belt tension, verifying the alignment of the pulleys, and ensuring that the belt is not twisted or bent during installation.
Starter Gear Considerations
Aftermarket starters may place additional stress on the BDL starter gear, leading to premature wear. The manufacturer recommends using stock starters to ensure compatibility and longevity. If an aftermarket starter is used, it must be tested for compatibility and adjusted as necessary.
Manufacturer Capabilities and Future Developments
BDL is expanding its product line and manufacturing capabilities. The company recently acquired GMA and Jamar brakes, as well as performance products for off-road vehicles. These acquisitions have allowed BDL to expand into new markets and develop specialized products for high-performance applications.
The company also has a strong background in machining, with over 50 CNC mills and lathes, as well as a gear-cutting department and a rubber manufacturing facility. This in-house capability enables BDL to produce custom components with high precision.
One of the company’s recent ventures includes the development of blowers for motorcycles, particularly for high-performance engines. The manufacturer claims to be the only company capable of offering blowers in stock and ready for immediate shipment.
Conclusion
BDL belt drive systems offer a high-performance alternative for motorcycle enthusiasts seeking precision, durability, and customization options. The installation process requires careful attention to detail, particularly in terms of alignment and component handling. Users must follow the manufacturer’s instructions closely to ensure proper operation and avoid premature component failure.
The ability to customize the clutch system with diaphragm or coil spring options, as well as adjust the number of springs, allows riders to tailor the clutch feel to their specific needs. Whether for stock or high-performance applications, BDL provides a versatile platform for motorcycle builders and enthusiasts.
By adhering to the recommended installation procedures and using stock components where possible, users can maximize the performance and longevity of their BDL belt drive systems.