HELP NEEDED- ribbed V-belt 4 PK 592 1150GSA

[albatross]

For the past hour I am trying to fit a new V- belt to my 2005 GSA.
the belt that came of was tight and same size.
according to realoem if the pulley wheel is 57.3mm it needs to be a PK 592 and not a PK 611
so checked the pulley wheel at the alternator and it is 57.3 mm.
the PK611 slips in no problem, but how the hell can you get the PK 592 over the pulley wheel????
I tried by sliding on the top and then turning the crankshaft, but no chance.
There got to be a technique,so anybody can give me some advice, would be VERY appreciated.
cheers

 

[Ian J Hartley]

This probably won’t help much but, When I replaced my polly V belt on my bike at 72K (Feb 2020) the pulley diameter is the same as yours 57.3mm

The belt that came off was marked:-
12.31.768141 - 692637 4PK592 CONTITECH

The belt that replaced it was marked:-
CONTITECH 4 PK 611 (592) ELAST

It’s been running fine for the past 12k miles.

There is some confusion about Polly V belts so Read post 3 of this link, it might help you understand the difference between BMW part reference and Contitech part reference.

https://www.ukgser.com/community/threads/alternator-belt-elast.283128/

 

[albatross]

Ian,that helps an awful lot…..hahah…been testing a 611 and that seems to fit well.
got both here, the PK 592 as well as an Contitech PK611 , exactly what you used.
wasn't really sure if I can use a larger one, but you answered that one…
i can’t believe they used such a tight fit , even with all tools available to me I could get it on..
never mind if you have to do that on the side if a road in an emergency..oh my
great Tx lot

 

[Santa-2512]

Dont know if its of any use, but just seen this trick to replace a belt on an early GS

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22:30 mins onwards

 

[albatross]

another interesting idea Santa…let me have a look and see if the 1150 pulley has any holes, which could be used….

 

[NeilDD]

No need.
When looking from the front the LH bolt is fixed and the RH bolt runs in a slot.

Loosen slightly the LH bolt and really loosed the RH bolt, swing the alternator down, fit the belt.
To tension put a large screwdriver under the alternator and lever upwards.
Tighten bolts all done

Screwdriver tip (c) Steptoe

 

[albatross]

Thanks Neil, I am gonna have a try…

 

[Mad Hatter]

I had the same problem when I last replaced my alternator belt. I ended up using the bigger belt in the end, even though in theory the smaller unfittable one is correct. The big ones work just fine and the upside is that on a GSA they give you a little extra room to wiggle the fuel tank balance pipe past the alternator

 

[DrFarkoff]

Jeez this much discussion for an alternator belt ?? It just has to spin and alternator to make current and not squeak!!
Fit the Belt that is easiest to get on and adjust the alternator height for correct tension and be thankful that it is an 1150 and not a 1200 (Zero adjustment requires the "Elast" belt)

Don't overthink it! Just do it!

 

[albatross]

Sure DF,I do agree. why such a simple belt change needs to become impossible because they use the tightest
f*** belt there is and it takes you 2 h working out it’s NOT a possible. Uttlery rediculous .., I have done a few on my GS and it was done in 20 mins if that.
So regardless I feel better that there are a few encountering the same issue and offering some advice…
cheers mate.

 

[Steptoe]

Feck me it’s a 5 minute job once you’ve removed the plastic alternator cover, on an 1150 forget about fitting the elastic belts, the 1150 has an adjustable alternator, unlike the 1200 which has a alternator fixed in place and can’t be moved/adjusted. Loosen the three 13mm bolts holding the alternator in its present position, let it drop down to its lowest position, fit a 611 belt, insert a pry bar or long screwdriver under the alternator and lever it up until the belt is tight, hold pry bar/screwdriver with one hand and tighten one of the alternator bolts, remove pry bar and tighten other two bolts,

 

[Old Codger]

I’ve sent you a pm Albatros

 

[albatross]

Step I have fitted a 611 in 5 min, all done as you said..
omly thing that got me how the feck are you to get the other one on there…never mind ,

 

[DrFarkoff]

Step I have fitted a 611 in 5 min, all done as you said..
bg thing that got me how the feck are you to get the other one on there…never mind ,

Does it "really" matter ?

Or are you OCD and it says it should be that belt?? Then it should be that belt??

How many times have there been typos in Manuals never mind just the parts catalogues?

Well besides all that You are one up on RealOEM

You now have a working and well adjusted alternator drive belt and that is the important thing

 

[albatross]

 

[Steptoe]

Step I have fitted a 611 in 5 min, all done as you said..
omly thing that got me how the feck are you to get the other one on there…never mind ,

It is fairly easy. Lots information in the 1200 section as they have no choice but to fit an elasticated belt…, another benefit in fitting a 611 belt on a 1150 ADV is the raised alternator allows more room and easy for pulling the fuel tank link hose Q/D under the alternator when removing the tank

 

[Pekkavee]

Have a look in here