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| ZXR750H2 Charging system; Alternator Belt Tension | |
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| Tweet Topic Started: Mar 18 2007, 07:49 PM (2,483 Views) | |
| greenmeanmachine | Mar 18 2007, 07:49 PM Post #1 |
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Hi All :123 My first post. I have a Zxr750H2 which had been standing in a friends garage for a few years before I got it. The bike stopped after a few miles riding at night. The battery was flat, and took a long time to charge so I replaced it as it was old. I fitted a new battery but the same thing happened again,bike stopped and would not restart. Battery flat again. I checked the alternator output voltage and it was zero. I found the Alternator belt had snapped due to it corroding onto the pulley while it was standing in the garage. Also the plug from the alternator had burnt out. I replaced the plug, cleaned out the alternator which had bits of belt reinforcing metal wires in it, and put a new belt on.(an awkward job to say the least, especially trying to keep the belt on squarely onto both pulleys). The bike has now run for 6 month's (average mileage) with no problem until today when I found the belt had broken again. The inner face was a bit rough but the belt had snapped cleanly.(Bando rib-ace 7PJ290). I bought a haynes manual a while ago which while reading it today happens to say you need special tools to tension the belt. The question is, How do you tension the belt correctly so it will last a bit longer than 6 month's without having to buy special tools which I will probably only use once?.Looking forward to your suggestions. Thanks
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| greenmeanmachine | Mar 22 2007, 09:12 PM Post #2 |
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Hi again :123 I received the new belt today (about £17) and I am hoping to fit it this weekend so I can go up to Cadwell. (Subject to the snow fall) As I don't want to break down again has anyone fitted one of these belts before and can give me any tips on how to tension it Thanks
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| RedRock | Mar 23 2007, 08:22 PM Post #3 |
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Hi and Sorry, can't help you out. Do you have a Haynes manual to help you?? Good luck
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| greenmeanmachine | Mar 24 2007, 12:46 AM Post #4 |
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Back again. I must apologize as my computer is so old it has just about hacked the ENIGMA code. I have also just gone on broadband which is a bit quicker than the old windows 95 system I have been using. I have just read my questions and realised that the waving hand (smiley) that I have been using :123 has a, what I call, a secondary meaning which I did not realise existed on the old slow system. This is something which I would not use and apologize for the misunderstanding. |
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| greenmeanmachine | Mar 25 2007, 06:36 PM Post #5 |
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Back from Cadwell today, great weather. I got the belt fitted this morning. I tensioned it using 'moderate' pressure and it did not squeal. The thing which gives me the most confidence is the fact that the new belt is physically thicker than the last one. Both came from a Kawasaki dealer, the first was in stock but the second one had to be ordered from a distribution centre. Belt is a Bando Rib-Ace 7 PJ 290 (poly V). The first belt, which snapped after 6 month's was 3.05mm overall thickness, (1.55mm was the thickness of the rubber 'backing' and the rib was 1.5mm thick). (There was 6 month's wear but this was in the rib area.) The second belt was 4.09mm overall thickness, (2.3mm was the thickness of the rubber 'backing' and the rib was 1.79mm thick). The extra thickness of the 'backing' was quite noticeable when the two belts where placed side by side. I can only take it that the first belt was 'old' stock and the new one was 'newer' stock. Hope this others in the future. |
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| RedRock | Mar 28 2007, 08:14 PM Post #6 |
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Glad you got sorted - Cadwell I'll be there in May
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| greenmeanmachine | Apr 3 2007, 07:33 PM Post #7 |
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Run the bike for a few hundred miles now and guess what, the belt just has started to squeal again on start up and mainly in third gear. I have put a bit more tension on so hope it will solve the problem. |
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![]](http://z4.ifrm.com/static/1/pip_r.png)
How do you tension the belt correctly so it will last a bit longer than 6 month's without having to buy special tools which I will probably only use once?.
Thanks



Sorry, can't help you out. Do you have a Haynes manual to help you?? Good luck
others in the future.
I'll be there in May
12:54 AM Jul 11
