03 Pitbull Pulley Problem

[joshdell]

Hey guys, Im Brian and live in Dallas. I have an o3 pitbull. The other day i was pushing the bike and heard something making a not so good noise coming from the belt pulley area. I knew it wasnt good so I tore the bike down to find that the nut that holds the pulley had come off and the locking plate that locks the nut on was also off. the bolts had been sheared off. WTF? I did buy a TevTech tranny for it 2 years ago. the baker was a bit out of range at the time.
My first question is irrelevant. But I am trying to figure out how the bolts on the locking plate got sheared off. my first thought was the nut came off and wile spinning around got in a bind with the plate. but the nut couldnt come off because of the plate. I prolly have 20K miles on this tranny. I ride daily.
My second question is how do I tighten this nut down? the tranny mainshaft is way too long and too big around for any sockit I have., and a wrentch just aint gona get it. is there a special tool for this? any help would be appreciated. i just wana get back on the road. Thanks.

 

[bigdogtech01]

Most likely the pulley nut was not tightened to 80 ft lbs from day one, or not enough or any red locktie on threads, so it came loose...once that nut starts to loosen up, it moves back and forth enough to eventually shear the bolts off.
I used to make them sockets and sell them on Ebay for around $60 ( Baker and H-D want close to $200 I believe)..I must have sold a good 50 of them...been a while..might have to make up some more. I'll check to see if I have any laying around and if I do, I'll let you know.
It's left hand thread by the way. Spec is Red locktite to 80 ft lbs.
Any play on the input (main shaft) shaft?

 

[joshdell]

The mainshaft looks good. I looked at the harley site to get a look at the tool and I can make that I believe. Im gona see what I get. any suggestions on how to hold the pulley wile I torque it down?

 

[bigdogtech01]

The mainshaft looks good. I looked at the harley site to get a look at the tool and I can make that I believe. Im gona see what I get. any suggestions on how to hold the pulley wile I torque it down?

Hold pulley with belt in place using rear brake. One other thing you should check is pulley itself. If it became loose and has been loose for a while, it's very common for the splines of the pulley to become worn. They are softer material than that of the main drive gear splines. Clean splines of pulley good with a wire brush and some solvent, then inspect to make sure they are nice and smooth all the way across...if any lips are on outer edge, facing primary...it will need a new pulley.

 

[joshdell]

Well Shit! I thought I was home free Andrew. I checked the pulley over a little better and, You called it. The splines are wasted so I am going to have to order one. Waiting to hear from a friend of mine to see if he has one first. Question, do the splines of the mainshaft come all the way out to the face of the pulley? ALso My invention to tighten the pulley doesnt look like it is going to work. care to let me in on how you make those puppies? I appreciate the heads up on the splines. Im glad i didnt put it back together. Thanks!

 

[bigdogtech01]

Well Shit! I thought I was home free Andrew. I checked the pulley over a little better and, You called it. The splines are wasted so I am going to have to order one. Waiting to hear from a friend of mine to see if he has one first. Question, do the splines of the mainshaft come all the way out to the face of the pulley? ALso My invention to tighten the pulley doesnt look like it is going to work. care to let me in on how you make those puppies? I appreciate the heads up on the splines. Im glad i didnt put it back together. Thanks!

The sockets I made from laser cut 1/2" thick steel, I TIG welded the socket side and 1/2" drive side on both ends of 2" DOM tubing...I'll look tomorrow to see if I have any laying around...
As far as the splines go, the Main drive gear does not go all the way to end of splines on pulley...lacks around .060" or so. Glad you caught it before putting it all back together :2thumbs: