How to Rebuild Timing Belt Idlers


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SteveB123
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How to Rebuild Timing Belt Idlers

Postby SteveB123 » Mon Apr 23, 2012 7:46 am



Most of the research and work for this was NOT done by me, I'm merely documenting the method I used.
http://www.ngwclub.com/gallery/d/129080-1/TENSIONER-REBUILD-JCS.pdf

The benefit of this procedure is cost. Next time the belts are changed on this bike, the bearings won't be inspected, they'll just be changed, as easy as swinging wrenches.

While into it for a belt swap, I noticed what appeared to me to be some transference onto the bearing. Possibly from a slight wobble of the bearing, causing the belt to slightly smear across it? I don't know, but the bearing certainly isn't tight, and when you're in this far....
Existing bearing
Existing bearing


Disassembly: I used a thin cut off wheel in a hand held grinder to separate the actual bearing from the backing plate. Lots of sparks, this is pretty tough material.


Cut in the slot between the bearing and the backing plate.


Clean up any roughness on the backer plate with your preferred method.


As the centre hole of the bearing is 10.3mm, I'm using a 10mm bolt. i think it's 25mm long, but check your own measurements.
Drill out the hole that was left in the plate to 10mm....I used a 13/32 bit. Close enough, as everything is tightened down here, and nothing moves between the bearing, the bolt and the backing plate.


Brand new idler bearings from Napa.....late model Kia/Hyundai fitment.


10mm high quality bolt, washer and locking nut, and crank it down.


.....and away we go!


As always, YMMV.

Cheers.

Steve


Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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virgilmobile
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Re: How to Rebuild Timing Belt Idlers

Postby virgilmobile » Tue Apr 24, 2012 8:26 am

Great pix and easy for any wrench head.And I appreciate the part number too.Probably cheaper than a OEM replacement too. :)
I don't see any changes I'd make other than lock tight or peening the nut.

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SteveB123
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Re: How to Rebuild Timing Belt Idlers

Postby SteveB123 » Tue Apr 24, 2012 9:30 am

Rockauto has the bearing for ~$20, Bikebandit has the tensioners for ~$85 ea.
My local cost at Napa canada was ~$36, still a considerable savings over Mother H.

Bolt/nut pic is actually inaccurate, I used the locknut sitting to the side, and cranked it down tight. It's not going anywhere. :)
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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virgilmobile
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Re: How to Rebuild Timing Belt Idlers

Postby virgilmobile » Tue Apr 24, 2012 10:41 am

It's not nice to fool Mother nature.
Thanks for the info.
It is OK to fool Mother Honda tho.. :D

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Thu May 07, 2015 6:16 pm

this might be an old posting, but its gonna come in very handy when i replace my stock tensioner rollers with new ones. i loosened up on the tensioners today and they are still making noise, so i guess im gonna have to change them. my local O'reillys auto parts store has them for only $21.99 each and with my military discount they will be even cheaper.

stuart.

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SteveB123
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Re: How to Rebuild Timing Belt Idlers

Postby SteveB123 » Fri May 08, 2015 2:08 pm

Three years on, mine are still spinning just fine.
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Sun May 10, 2015 8:40 pm

i just finished redoing one of my belt tensioners exactly like you did it, and man, you weren't kidding about the sparks, it looked like the 4th of July in my garage lol. after i cut thru the outer roller shell, i started to cut thru the inner, and what i couldn't cut with my angle grinder i wound up finishing it off with my reciprocating saw. got the bracket nice and smooth and used a 10mm bolt with a flat washer inside and a nylon lock nut and used my 3/8th drive impact gun to tighten that mother down. now i can do the other one tomorrow, and the best thing is i didn't have to remove the radiator to get to them.

now i have just one question, as far as tensioner adjustment, do i apply a little extra pressure on the tensioner to make the belt tight, or just let the tensioner spring adjust it and tighten the bolts down and leave the belts as they are on the rollers even if they are a little loose, (more than 1/4") because my manual doesn't show or say how tight or loose the belts should be.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby spiralout » Sun May 10, 2015 10:39 pm

roadwanderer2 wrote:now i have just one question, as far as tensioner adjustment, do i apply a little extra pressure on the tensioner to make the belt tight, or just let the tensioner spring adjust it and tighten the bolts down and leave the belts as they are on the rollers even if they are a little loose, (more than 1/4") because my manual doesn't show or say how tight or loose the belts should be.

The answer is in the link I gave ya here http://goldwingdocs.com/forum/viewtopic.php?f=4&t=27010&p=154911#p154911

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Mon May 11, 2015 5:59 am

ok, i got it, thanks.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Mon May 11, 2015 10:09 am

ok, both new belt tensioners are now on the bike, properly adjusted, everything back together, took it for a test run thru the neighborhood and it runs really good. no more pulley noises, didn't have to remove the radiator this time, just unbolted it from the brackets, took off the lower hose and pulled it forward just enough to get my hands behind it to the covers and tension bolts. total cost was under $50.00 including new bolts, washers and locking nuts. now all that's left is to replace both tires and im good to go.

NOTE: the right side tensioner bearing was so bad that when i cut it open, all the little roller balls were dry, burnt and scored. glad i did these now instead of waiting until next month. these bearings wouldn't have lasted much longer. this was a disaster waiting to happen.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby littlebeaver » Wed May 27, 2015 2:53 pm

My Jeep I was so proud of made it down to Destin, Florida and back, well lol almost anyways,,,lol, the Mother freakin idler tensioner pulley(non adjustable one) decided to go out on the engine making the belt snap like a rubberband being pulled to tight :shock: ,, my daughter Amanda and I were 1 hr. from KC on I-70 and it was raining, when I had checked that tensioner before we left and I spun it and felt it and it was good, so you never really know when one of these buggers are gonna go on you, sometimes they will make noise and sometimes they will just go and boy this bearing was gone man, granted we ran the crap out of the engine doing 85 mph most the way just trying to keep up with traffic....lol Wife came and got us and we went back to KC we had it gone by 8:30 the next morning with new parts,, ..I may do this modification just because I don't want this to happen on my motorbike :shock: ...

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Wed May 27, 2015 3:02 pm

sorry to hear you had some trouble with your vehicle, but glad you finally made it home again. doing the tensioners on your bike now might not be a bad idea, do them now and avoid the problems they can cause later. im glad i did both of them now because i don't know how much longer they would have lasted. only thing im sorry about is i didn't put them on right away when i had the belts off the first time.

the way that SteveB described and the photos he posted were a huge help when it came time to see how he did his.........THANKS STEVEB :D. the only problem i ran into was my disk grinder wasn't thin enough to go between the roller and the plate, so i had to cut THRU the roller to get TO the plate, and once it was apart, the rest was easy.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby littlebeaver » Wed May 27, 2015 4:21 pm

Yeah this is a kiss ass post on rebuilding the tensioner, Thanks SteveB123,,, You are the man...I like it... :D

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Wed May 27, 2015 7:24 pm

the pulleys you can get from O'reillys auto parts, (T42015) for around 22 bucks each, if your a veteran, you can ask for a 10% military discount. when you put them onto the pulley plate, use an air gun to lock the nuts down nice and tight. a 10mm x 1" is the perfect bolt size to use along with a metric flat washer just like SteveB says and shows in his posting.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby littlebeaver » Thu May 28, 2015 7:36 am

Kick ass post is what I meant...oooops :lol:

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Re: How to Rebuild Timing Belt Idlers

Postby roadwanderer2 » Thu May 28, 2015 8:53 am

littlebeaver wrote:Kick ass post is what I meant...oooops :lol:



i know you did.

stuart.

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Re: How to Rebuild Timing Belt Idlers

Postby littlebeaver » Thu May 28, 2015 11:24 am

I have an extra set of idlers I purchased several years ago, actually I replaced the ones I have on now and I Kept the others, those would be the one's I will replace and then install on my Ginger.... That pulley idler is off a Hyundai Elantra 96-97 1.8, or the Kia Spectra Ex. 2004-2007 2.0, thank's again for the reference # T42015 I shall retrieve one set for sure...I should have taken a photo of my destroyed idler pulley from my Jeep....It's got two new pulley's now and sounds like a brand new engine again.... :D I highly recommend you change the one on your automobile if it's high in miles, good insurance for sure...Cheap insurance...I'm good to go to Destin Fl. again, love it down there...

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Re: How to Rebuild Timing Belt Idlers

Postby triwing » Sun Feb 21, 2016 6:53 pm

Will these bearing replacements work on my 1200's & 1500 Wing's? :geek:

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Re: How to Rebuild Timing Belt Idlers

Postby Rednaxs60 » Sun Feb 21, 2016 10:21 pm

triwing wrote:Will these bearing replacements work on my 1200's & 1500 Wing's? :geek:


Rebuilt the tensioners on my '85 LTD just this past month with the T42105 idlers.

I was pleasantly surprised how easy this modification is to do with minimum tools. Items:

hacksaw
Punch/chisel - to remove old stud after hacksaw used to remove old idler
17 mm socket
6 mm hex drive
10 mm by 25 mm flat countersunk bolt
nylock nut with flat washer
Gates 42105 idler

Total cost for this mod is approximately $90.00. I did not need to use a 1/2 inch drill bit that I bought specifically for this, so the resulting would have been $84.00, significantly less than 2 new timing belt tensioners from mother Honda - $200.00 up here.

Here are some pictures of the old/new tensioners:
This one shows the old idlers cut off the base plate and the new idler next to it.

This picture shows the base plate with the old bolt punched out and the countersunk opening on the back side of the base plate.

This picture shows the new idler installed and you notice that the securing bolt is slightly proud at the back.

This picture shows the back of the base plate where I trimmed the securing bolt so it is flush. I can still use a hex drive to remove the bolt should I have to replace the idlers.

These last two pictures show the finished product:


I would recommend using a hacksaw to remove the old idlers. A new blade and 15 minutes and the old ones are off. Punch out the old bolt and install new idler(s). The 1500 uses the same idlers. I would also recommend replacing the tenisioner springs with new, small cost but ensures proper tension on the idlers when installed.

Good luck.

Ernest
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: How to Rebuild Timing Belt Idlers

Postby triwing » Mon Feb 22, 2016 6:51 am

Thanks; :) Like the counter sunk alan idea much better than a bolt head on the back! :D

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Re: How to Rebuild Timing Belt Idlers

Postby triwing » Sat Feb 27, 2016 3:03 pm

Just rebuilt a set of timing belt adjusters, :D they look just like the pic's do :o Thanks :lol:

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Re: How to Rebuild Timing Belt Idlers

Postby Rednaxs60 » Sat Feb 27, 2016 3:10 pm

triwing wrote:Just rebuilt a set of timing belt adjusters, :D they look just like the pic's do :o Thanks :lol:


I torqued the idler bolt to 30nm. Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

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Re: How to Rebuild Timing Belt Idlers

Postby triwing » Sat Feb 27, 2016 4:39 pm

Didn't measure the torque, & used 3/8, heat treated, counter sunk, 5.5mm drive bolt's, washer's, with steel stover nut's, to lock everything down. Stronger than the plastic lock nut's, as they don't crack. Have yet to grind the back smooth, only reason i did this in the first place, was because there was an old set lying around, having a rebuilt set around, is better. :lol:

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Re: How to Rebuild Timing Belt Idlers

Postby mlmaher » Sat Apr 09, 2016 12:35 pm

Does that bolt need to be flush in the back of the mounting bracket? Some of the posts aren't clear on that. Thanks

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Re: How to Rebuild Timing Belt Idlers

Postby Rednaxs60 » Sat Apr 09, 2016 1:36 pm

In my opinion yes. There is a piece of the casting that is quite close to the back of the tensioner base when installed. I would definitely make it flush.

Cheers


"When you write the story of your life, don't let anyone else hold the pen"

Ernest


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