When we first heard a rumor about a 3-inch open beltdrive system being developed for the Sportster, we were very excited to see what the finished product would look like, and of course to see one installed. Naturally, all of our friends who ride Sportsters were waiting on pins and needles to get the inside scoop on when this kit would be made available to the public. They didn't have long to wait.
Well, rumor became reality at the last V-Twin Expo in Cincinnati, OH, as Evolution Industries unveiled its 3-inch beltdrive kit for the Sportster. The response to the system was phenomenal. After talking to the people from Evolution Industries about what went into the creation of this beltdrive system, we knew right then and there that we had to get our hands on one and do the install. They were more than kind enough to oblige.
As luck would have it, our friends from LifeStyle Cycles in Anaheim, CA, were working on a custom '03 Sportster project that was a perfect candidate for the Evolution Industries beltdrive. The '03 Sporty already had a stretched tank and custom paint and pipes, and would really look sharp with an open primary. We got the kit down to LifeStyle Cycles and followed along as mechanic Anthony Walton did the expert install on this innovative and unique beltdrive system. During the installation process, LifeStyle Cycles found a couple of ways to improve on this already incredible setup, so you get to see them here first. But enough talking-let's dive right in to the installation process of this beltdrive system.
The Evolution Industries Sportster...
The Evolution Industries Sportster open-primary kit comes complete with everything you see here. The kit is not only complete, but it looks awesome, too.
First things first; any time...
First things first; any time you work on a bike, disconnect the battery. Next, Anthony drained the primary fluid, removed the shift linkage, and took the adjustment out of the clutch cable. Then he removed the derby cover, followed by the shift-arm shaft. At this point he was able to unbolt and remove the primary cover and gasket.
With the derby cover removed,...
With the derby cover removed, the clutch-release mechanism was taken off with a small flathead screwdriver. The snap ring on the clutch assembly came off next, followed by the adjuster screw plate, which allowed access to the clutch hub nut.
Next, the engine sprocket...
Next, the engine sprocket was removed, along with the clutch assembly and primary chain. The eight bolts securing the sprocket to the rotor were then removed so the sprocket could be pressed out of the rotor (the rotor will be reused later).
Here are the parts that will...
Here are the parts that will be reused for the new beltdrive: rotor, clutch adjustment screw, retaining ring, clutch inner and outer ramp, three bearings (not shown), coupling, nut, locking plate, spring, and washer.
After cleaning the primary...
After cleaning the primary area with contact cleaner, it was time to start the install of the new Evol 3-inch beltdrive unit.