Section 04 TRANSMISSION
Sub-Section 05 (PULLEY DISTANCE AND ALIGNMENT)
04-05-1
PULLEY DISTANCE AND ALIGNMENT 5
GENERAL
The pulley distance we will refer to in this section,
is the space separating the drive and driven pulley
outside diameters (Z measurement).
This basic distance is provided as an assembly
guide and indicates the dimensions between
which satisfactory belt deflection will be obtained.
Both pulley distance adjustment and pulley align-
ment must be carried out to ensure the highest
efficiency of the transmission system. Further-
more, optimum drive belt operation and minimal
wear will be obtained only with proper pulley
alignment.
CAUTION : Before checking pulley adjust-
ment, the rear suspension must be mount-
ed on the vehicle and track tension / alignment
must be done. Always check pulley adjustment
after suspension is adjusted.
WARNING : Failure to correctly perform
pulley alignment may cause the vehicle to
creep forward at idle.
All pulley alignment specifications refer to :
X = Distance between straight bar and drive pul-
ley fixed half edge,
measured between pul-
leys
.
Y = Distance between straight bar and drive pul-
ley fixed half edge,
measured at the end of
straight bar
.
Z = Distance between outside diameter of pul-
leys.
GENERAL PROCEDURE
Remove belt guard and drive belt.
By turning and pushing the sliding half, open the
driven pulley. Insert a straight bar 9.5 mm (.375 in)
square, 48 cm (19 in) long or the proper alignment
template into the opened driven pulley.
Measuring Procedure
Using Straight Bar :
Always measure distances X and Y from the far-
ther straight bar side (including its thickness to the
fixed half edge.)
1. Straight bar
2. Front of vehicle
The distance Y
must
exceed distance X to com-
pensate for the twist due to the engine torque.
Nominal Value Procedure and Quick
Alignment and Distance Check
Alignment template tabs must fully contact fixed
half of drive pulley.
Pulley distance is correct when tab contacts both
pulley halves.
Refer to below chart for proper alignment tem-
plate.
;
A00D0WA
1
2
Z
X
Y
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