Belt Kit Install on Standard Crazy Cart w/ XL Motor Swap

Belt Kit Install on Standard Crazy Cart w/ XL Motor Swap

🧰 Step 1: Prep & Disassembly

🛞 Remove the wheel from the cart
🔩 Remove the factory chain tensioner completely
⚙️ Remove the XL motor from the cart

⚙️ Step 2: Motor Pulley Installation

  1. Remove the sprocket from the XL motor
    ⚠️ IMPORTANT: The sprocket uses reverse threads
    👉 Righty = loosey | Lefty = tighty

  2. Install the Head Turner belt drive motor pulley onto the motor shaft, make sure that the set screw sit directly on the flat side of the shaft/threads. Otherwise the shaft will spin and the pulley will not.

  3. Do not tighten the set screws yet!

    • ✅ Set screws must face away from the motor, toward the fork side. 

🔄 Step 3: Reinstall the Motor

  1. Reinstall the XL motor back into the cart but DO NOT TIGHTEN YET, leave the bolts slightly loose. This is so we can install the belt without forcing it over the lower pulley.
    ⚠️ Clearance is tight here — this is normal

🔧 Belt Tension Adjustment (IMPORTANT)

  • We include (4) extra black washers. If you do not use at minimum 2 washers your belt tension will more than likely be TOO TIGHT. This can lead to belts snapping or shattering the lower pulley (has been seen twice now). If this is the cause of your belt or pulley breaking you will be responsible for the cost of replacement.

  • These are washers used as shims between the motor and the fork to ensure the belt is not too tight

  • ➕ Add washers 4 only if the belt feels too tight with 2 washers

  • ➖ Remove washers if more tension is needed (IE the belt slips)

  • When adding only 2 washers, you can only add 2 on the front, or 2 on the rear. Do not add on just the left or right side, if this is done you will angle the motor and cause the belt to slip off.

👉 This allows you to fine-tune belt tension without forcing anything

🛞 Step 4: Wheel Pulley Installation

  1. Remove the factory Crazy Cart wheel sprocket

  2. Install the Head Turner belt drive wheel pulley

🧩 Hardware Note:

  • Use the (3) black washers and black bolts provided

  • These are required for mounting the new wheel pulley

🔧 Tighten evenly in a cross pattern and ensure the pulley sits flat, be careful overtightening these as the wheel is made of aluminum that will pull threads is torqued down too hard.

🧩 Step 5: Belt & Wheel Installation (Final Step)

  1. Loop the belt over the upper (motor) pulley first (as said earlier make sure the motor slightly loose when installing the belt) You don’t want to force the belt over the pulley like you would a chain. This could lead to pinching the belt and causing premature failure.

  2. 🛞 Reinstall the wheel

  3. Start the belt onto the lower (wheel) pulley

    • Spin the wheel while pushing the belt on

    • The belt will walk itself into place

Final Step:

  • Tighten your motor with belt installed on both pulleys, align your motor pulley with the wheel pulley, check this by spinning the tire a few rotations and see where the belt sits. If it does not sit evenly in the middle push in or pull out the motor pulley to adjust the belt. If for some reason it can't be aligned properly we provide further instructions below and this is where you will utilize the larger silver washer we provide.
  • The belt should sit evenly on the motor pulley. Now you can tighten your motor pulley with the supplied set screws. 

Belt Tension Adjustment (IMPORTANT)

  • If the belt feels too tight, we include 4 black washers

  • Install washers between the motor and the fork to loosen belt tension, start with 1 washers under each of the two bolts that are forward when your steering wheel is pointing forward. Forks vary in length, on average 2 of the 4 shims are required to be used. Make sure not to put just on the sides.

✅ You’re Done!

Your Head Turner belt drive system is now installed.

Enjoy:
🔇 Massively quieter operation
⚡ Smoother power delivery
🔥 Cleaner, stronger drivetrain


For carts without drum brakes read below:

On some carts due to weld on (figure 1.) the fork and possibly bent forks we send a silver washer to go on your axle. This washer will go in between your fork and black spacer on the non belt drive side. As show in the picture below (figure 2.).


Figure 1. the weld on the left side of the fork holding on the tab can sometimes intervene with your new wheel pulley bolts. This is when a washer is needed on this side.


Figure 2. This will help get the belt aligned right in the middle of your pulley if you notice the belt is running more towards the fork instead of centering.

Back to blog