That flat mark on the pulley is not cast....somebody did that with a chisel and a hammer.  I have never seen the factory do something like that.....it is a mystery who did it.

The easiest way to get the front pulley mounted....is too loosen the rear axle and loosen the adjusters to take the tension off the pulleys.  Leave the adjusting lock nuts where they were and you can get the adjusters where they where.....or just look at the index marks on the sides of the swing arm and but it back in the same place....or measure how far the adjusting screws stick out the back.

Dave wrote on 02/15/18 at 03:17:40:


Dave ,what's the mystery? the bike had only one PO. For some unknown reason the pulley let loose ,and he took the pulley off ,applied anti-seize and put it back on using a chisel to bend the washer. Knowing the bike was leaking oil ,but not knowing the seal was damaged he then parked it for the remainder of ten months and then sold it.
       Next mystery, why is there an O-ring and collar? why wasn't the outside seal made larger so it could ride directly on the shaft ? I believe the answer is heat. the outer seal has to deal with shaft speeds of 5000 +rpm ,and I'm guessing that it must be made of a soft silicon based rubber ,that won't handle heat. The shaft and gears are bathed in oil at least 270 degrees ,the heat travels down the shaft until it reaches the pulley and nut.(hot runs to cold) . The collar jammed between the bearing and the pulley and spaced away from the shaft by the O-ring does not contact the shaft therefore the outer seal is protected from this heat. the pulley is not ,and is why I advised using Bearing mount (good to 500 F )rather than 609 (at 150F). Misalignment of the collar due to the pulley being loose also accounts for the damage found on the seal and O-ring  , it caused the O-ring to be pulled from the groove ( It is normally fixed in place due to it turning the same speed as the shaft and collar),and this allowed the collar to touch the shaft and transmit heat that melted some the seal ,which was found stuck to the outside of the collar.Which is why I said he should change the seals while he was at it.

OK it's all back together, I took the bolt off a second time to clean up and retorque as I wasn't happy with it. All seems good, belt is not riding to one side on the rear pulley. No sound at all when wheeling it in neutral. However I did mangle the lock washer getting it against the nut, but it will do the job.

Oh yeah you'll be happy to know I got a 30" breaker bar for only $30 AUD, it's quite the weapon I can tell you.


@Batman, I've said it before and I'll say it again, the OP did not remove the pulley. He did not remove the tyre valve caps to put air in it. It was an impulse buy from someone who got caught up in the romance of the idea.