Owner's manual

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INSTALLATION INSTRUCTIONS FOR

BRUTE IV EXTREME

OPEN BELT DRIVE

FOR 1990 TO 2005 EVO & TWIN CAM Dyna

Models

with

OE MID CONTROLS

It’s common knowledge that a belt drive primary can provide advantages and service that a chain cannot, especially con-

sidering the new technology present in every belt. For dependable,high performance, long-life service nothing beats a

modern Primo Belt Drives primary-drivebelt-kit! Primo’s

long-time tradition of “Quality & Performance” has made our belt

drives the most popular in the world. That same quality & performance is now available in the Brute IV EXTREME™ 3”

wide open electric-start primary belt-drive for most Softail

style motorcycles. The Brute IV EXTREME™ is ideal for street-

performance, competition, and show-bike applications. Itlooks as good as it works. Carefully read and follow these instruc-

tions for a quick, convenientinstallation. If you have any questions regarding this installation call (562) 907-2600 and a

PRIMO BELT DRIVES technician will be happy to assist you!

Use of the word Harley-Davidson, various motorcycle model names & designations & OEM part numbers are for end-user reference or application information

only. No affiliation between Rivera Primo Inc. & The Harley-Davidson Motor Company exists or is implied by the use of said information. Rivera Primo Inc., Pro-

Clutch, Primo, and Primo Belt Drives are registered trademarks of Rivera Primo Inc. Unauthorized use is prohibited by law.

IMPORTANT SAFETY NOTE....

When performing any motorcycle work such as installing a belt drive it should be securely fastened in

an upright positionwith easy access to the primary drive. If you are working with a lift, fasten the mo-

torcycle securely to prevent it from falling.Always disconnect BOTH battery cables when performing

the following installation.

2108-0012

PLEASE NOTE: PICTURES CONTAINED WITHIN THIS INSTRUCTION SHEET ARE

ALSO USED FOR OTHER INSTRUCTIONS, SO THEY MAY NOT ACCURATELY DEPICT

THE BELT DRIVE THAT YOU HAVE PURCHASED.

Summary of content (8 pages)

PAGE 1
INSTALLATION INSTRUCTIONS FOR BRUTE IV EXTREMETM OPEN BELT DRIVE FOR 1990 TO 2005 EVO & TWIN CAM Dyna® Models with OE MID CONTROLS PLEASE NOTE: PICTURES CONTAINED WITHIN THIS INSTRUCTION SHEET ARE ALSO USED FOR OTHER INSTRUCTIONS, SO THEY MAY NOT ACCURATELY DEPICT THE BELT DRIVE THAT YOU HAVE PURCHASED. It’s common knowledge that a belt drive primary can provide advantages and service that a chain cannot, especially considering the new technology present in every belt.
PAGE 2
STEP 1 Begin by disconnecting the battery cables. Remove all of the OEM primary drive components including the inner primary cover, as well as the factory inner bearing race on the trans mainshaft. Check for leaky seals. Check & tighten, if necessary, the shift lever. Should you wish to change the gearing, now’s the time to install Primo’s billet aluminum rear drive pul¬ley. This pulley weighs 3 lbs. less than the stock one. It’s available in 29, 30, 32 & 34-tooth sizes.
PAGE 3
STEP 5 The stock OE shifter shaft used a wave washer to spring load the shaft. We use the same method, however our wave washer is larger. You should now remove the OE washer and install our wave washer onto the shifter shaft. STEP 6 Now it’s time to install the motor plate on the bike.
PAGE 4
STEP 9 Install the front pulley, rear pulley without the belt. Place the washer on the sprocket shaft, then thread the front pulley nut onto the shaft torqueing it to 150-165 Ft. Lbs. Next torque the transmission mainshaft nut 8090 Ft. LBs. Now check the alignment between front & rear pulleys and correct, if necessary, by adding spacing behind the front pulley (Primo sells these pulley shims in thicknesses of .020”, .030”, .050”, .075” and .
PAGE 5
STEP 12 Now begin assembling the rear clutch basket. At this time begin installing the clutch plates in the same order as received. The steel .120” thick plate first. Then a fiber plate, then steel and alternating until all plates are inserted. The last plate in is a steel plate. STEP 13 Coat the threads of the Pro-Clutch studs with Anti-Seize compound. This will prevent the shouldered nuts from sticking to the clutch hub stud threads during disassembly.
PAGE 6
STEP 17 There are 3 mounting bolts used to attach the nose cover. Coat each with 2 drops of Blue threadlock and torque until secure. STEP 18 At this time, adjust the Pro-Clutch according to specifications. Re-check until you are satisfied (see last page for adjustment specs). Finally, bend the lock tabs over against a flat on the nuts. This will prevent the nuts from coming loose. STEP 19 Assemble the 4 stand-offs to the motor plate. These pieces will act as the support for the outer guard.
PAGE 7
STEP 22 Install the white Delrin plastic washer on the outside of the guard onto the shifter shaft. STEP 23 Install the shift lever onto the shifter shaft. STEP 24 Install the foot peg and bracket to the frame.
PAGE 8
1-1/4-20 Bolt 2-10-32 Bolt 3-lock tab 4-thrust washer 5-pinion gear 6-spring 7-extension shaft 8-coupler PRO CLUTCH ADJUSTMENT BRUTE IV EXTREME CLUTCH PACK HEIGHT= 1.410” - 1.430” As delivered the Pro-Clutch clutch-pack requires no adjustment, the clutch pack height having been set at the factory. After thePro-Clutch has accumulated significant mileage, it may require some adjustment due to normal wear. Use the procedures out¬lined below if & when adjustment is required.