what you need to know about changing from 2003 to 2004 and up belt system.

[squidbuellie]

here is what you need...
front pulley
rear pulley
belt
pulley cover
bottom belt cover
and idle pulley tension arm (i used the same pulley)


the change over is pretty cut and dry, use a map gas torch to break loose the rear wheel pulley.
the motor pulley nut is reverse thread (turn clockwise to remove nut) do not put heat to the motor pulley if you do you can run the chance of melting the dust seal.
change the idle pulley arm throw the belt on and done.

[Blastonia]

What is the advamtage/difference?

[noone1569]

What is the advamtage/difference?

The 03 belt and system are prone to failure. I think it was labeled as a 25,000 mile belt, but they are known to fail early. Whereas the 04 + belt is a "lifetime" belt and should last "forever".

Thanks for posting this up, by the way. I've got a couple friends that just picked up '03s.

[squidbuellie]

What is the advamtage/difference?

The 03 belt and system are prone to failure. I think it was labeled as a 25,000 mile belt

i can only tell you what i have experienced. i have owned 6 different 2003 buell xb's and i have broke a belt on each bike except one, they all had around the same miles 8,000-14,000
the bike that the belt didn't break had 45,000 plus miles and that bike blew up.

but what i think is... the 2003 belts are just not strong, enough to handle the weight and torque. it probably doesn't help that im 245lbs ether.

but here are the differences between the belts.


2003 on the left, 2004-up is on the right


2004-up on the left, 2003 on the right

[buellxb9rs]

The last '03 style belt I bought was a upgraded version that is a lifetime belt. 20k or so plus on mine and it's good.

[thrstrmech]

squid...do you have the P/N's for all parts needed? can't find a parts catalog for an '04

[squidbuellie]

You can use any 04-10 xb9r/s or xb12r/s parts but the 2004 parts list is
Rear pulley G0400.1AA
Front pulley 40288-95
Idler pulley assembly G0604.1AA
Belt G0500.1AAH (new belt part number)
Pulley cover G0555.1AA
Lower belt guard M0560.1AA

[thrstrmech]

thanks a mil squid

[thrstrmech]

another question about the conversion, have read that there maybe a need to replace the rear brake cylinder for extra belt clearance...hmmmm, just looked at mine and the cylinder is actually further away from the belt than the heel/pedal bracket, if anything the bracket is the closest to the beltor did I read that right the first go around?

[squidbuellie]

Nope^^^
The belts are the same width, it is the thickness of the belt that is different.