This post documents replacing the alternator belt on my 2001 BMW R1150GS. Newer R1150GS’s use a slightly different belt and pulley, but the replacement procedure is similar. The major difference is the tensioning of the ELAST belt requires a different tool and procedure.
The tools I used:
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1993 through 2003 50A alternators:
Poly V: 4PK611, BMW part 12 31 1 341 779
Newer bikes:
ELAST: 4PK592, '04-on Oilheads and most Hexheads,
BMW part 12 31 7 681 841
ELAST: 4PK582, R12RT/Adv, BMW part 12 31 7 690 57
Stock BMW Belt for my bike:
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1) There are four nuts holding the alternator cover on. Remove them with the 4mm allen key socket.
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2) The cover should pull out slightly and then down.
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Alternator belt exposed:
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3) Using the 13mm wrench, loosen the three bolts holding the alternator.
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4) Pull the alternator down to put more slack on the belt if it didn’t slide down itself.
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5) Pull the belt off
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Old vs New belt:
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Mine was apparently past the 36,000 mile replacement. It was making a bit of a noise. Pieces of the belt had started to come off inside. Checking the belt tension is critical to belt life. Check when you change the oil.
Old belt:
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New belt:
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Notice the four ribs on the belt. They match up with the ribs on the pulley. Make sure to line them up when reinstalling the belt.
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6) The new belt just barely slipped back on.
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7) BMW has very specific belt tensioning specifications. Don’t be tempted to treat this like a car belt and do it by feel.
8) I had to turn the direction adjuster on the torque wrench to “loosen” not the tighten motion to get the alternator to lift.
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9) Using the 6mm allen key socket, extension, and torque wrench tighten the adjusting nut to 8 N-m. This will raise the alternator and pull it against the belt.
I found I needed to lift/tilt my gas tank slightly to have room with the torque wrench. See my air filter replacement guide for tips/photos.
BMW makes an adjustment tool that goes on the front rather than the back. Much Easier! I will think about getting it for the next tightening.
Adjuster for Poly V belts: tool 12 3 551, part 83 30 0 401 69
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10) While holding the torque wrench, use the 13mm wrench and tighten the other two nuts holding the alternator.
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11) Using the torque wrench and 13mm socket, torque all three nuts to 20 N-m.
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12) All three tightened up. Use the starter to crank over the engine a couple times, but don’t start it. This will help seat the belt on the pulleys. Loosen the bolts and repeat steps 7-11.
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13) Replace the alternator cover and tighten the four bolts with the 4mm allen key socket. The cover is plastic, so be careful not to over tighten.
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14) Cover replaced
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15) Check the belt again in 6,000 or the next time you change your oil.
16) Go for a ride!
Good pictures/discussion of the Poly-V vs ELAST here.