What's on Gas Man's Lift [kills even your high speed internet]

[derf]

Stuck bolts suck, you need to use a good penetrant, wd40, liquid wrench, or PB blaster (best).

[Gas Man]

Originally Posted by derf

http://www.amazon.com/Haynes-Suzuki-...6&sr=8-1-fkmr0

Everything that you really need to know

That is ok but a manual doesn't make you mechanical.

Originally Posted by psychochild28

Sweet. Thank you!

Still would be nice to have the use of his knowledge and garage....

Well its open... just need to get up here.

Originally Posted by derf

Stuck bolts suck, you need to use a good penetrant, wd40, liquid wrench, or PB blaster (best).

spray a good penetrant and wait.. then again and wait more... time is your friend with penetrating oil

[Mr Lefty]

Originally Posted by Gas Man

That is ok but a manual doesn't make you mechanical.



Well its open... just need to get up here.



spray a good penetrant and wait.. then again and wait more... time is your friend with penetrating oil

VERY TRUE... best thing to do when you get a stuck bolt is go buy some PB BLASTER... a 6-12 pack... and a burger or two... spray... open a beer, start on the burger... when your done with the first beer... go back... spray some more pb blaster on it... and continue...

I don't recommend anything more than a 12 pack... as some how... my buddy in AK got the beer and pb blaster confused... hilarity ensued

[Gas Man]

A quick add in. I did the work and created a how to to install it... so the names and shit won't make sense to you.

How To: Install your Karata Open Belt Primary [with OBS]


So you have a new fancy Karata Belt Drive for your BDM.

More specifically one of these http://www.karata.com/intimidatorbigdog.htm

What a batch of SIIICK HOTNESS! Right?

Hats off Jim at Karata. This is my first hands on expierence with his products. AMAZING! The invisible starter, solid piece backing plate inner primary is an nice chunk of metal. WOW!

So let's get it installed...

Bike and financing of this adventure provided by Trainguy!

His 2008 K9 prior to said HOTNESS.



Drain your primary oil for the last time.


Remove the outer primary



Loosen clutch freeplay on the down tube & pull the clutch rod. Notice I only pulled it far enough to clear the end of the trans input shaft. Barely enough room to do so behind the V&H BR2 pipes.


Pull the side covers to gain access to the starter



Pull the starter





Pull the four 1/2" bolts holding the diaphram spring on


Also, loosen the primary chain tensioner shoe.

Remove the pressure plate (set aside cause you need to reuse the clutch rod cup from the throw out bearing assembly).


Grab your impact and remove the motor/crank nut (standard thread) and the clutch basket nut (left handed thread).


Now slide the entire assembly off the shafts and set aside.


Bend flat the locking tabes on the inner primary mounting bolts (8).


Remove the 8 - 1/2" bolts holding the inner primary to the motor and trans. Also, the 2 allens on the front of the primary to motor. Once these are pulled, remove the inner primary and put away.



The scraps of war


At this point be sure to clean off the threads on the 2 shafts for proper adhesion of the red loctite.

During assembly please take use of your provided Karata instructions. This is not an attempt to circumvent these vital instructions. Just to aid.

Pull all the o-rings on the trans and motor (only 1). This includes the dime sized mounting o-rings, and shaft input o-ring. The motor has 2 more dime sized o-rings and the large black o-ring on the outer ring. These will not be re-used.

[Gas Man]

continued

Karata says to loosen the trans mounting bolts to ensure proper alignment and fitment. We trial fit the inner primary a few times and once torqued into place checked the mating surface of inner primary to motor & trans with a feel gauge. They need to be perfectly flush.



Be sure to use red loctite and torque these mounting bolts to bdm specs.

Install the provided motor and trans spacers on the shafts.

Motor:


Trans:


Slide the pulleys on the shafts, check pulley alignment with a straight edge. Then we red loctited and torqued the provided motor and trans nuts. Checking pulley alignment once again. This is also covered in the Karata instructions.



Install the clutch plates and pressure plate (with re-installed/re-used bdm cup placed into the pressure plate)


As you can see we chose the medium grade 80 lb green springs.

Slide your belt on the pulleys. Take note that Karate suggests against using any screw driver prying. A rubber mallet and/or your hand will do the trick. This is true. It goes on with ease.

At this point either install your pulley covers or continue and install your OBS bearings and OBS plate.

To install the OBS, its a simple matter of bolting the bearings to the pulleys with the ten 1/4" stainless steel bolts. Sliding the plate onto the bearing supports, which can be tricky but not hard. A little finese.

Top it off with the caps and six 1/4" bolts holding the plate on.


Now if this don't tweak you, then you're dead.



Another great project. What a FANTASTIC mod and a great product!

[Rider]

So is there any performance gain in putting on an open primary? It looks heavier that the stock setup. ie, more rotational mass producing less overall power.