Hi I am trying to replace the alternator belt on my 2003 1150 gs the one with the small balance wheel on the front of the alternator pulley. The new belt is the same No. as the one I cut Off but I am having difficulty getting the new one on . The Alternator is hard against the engine casing so I cannot get any more free play there I am trying to wind it on placing the belt over the alternator pulley and attempting to wind it onto the engine pulley by turning the engine with a spanner on the pulley nut !!!!!! What am i dong wrong ??
the Belt No. is 592 Elast belt I have thought I might have to resort to getting a slightly longer belt But surely I should not have to go that route ? HELP PLease

I know little about the 1150's so can't help much, but I DO know that there are two different belts depending on serial number, so maybe it's wrong despite the same number. I know, that's weird, but I've seen a lot of weird things...
Your technique sounds fine to me.
See this page for good clear instructions.

Good luck, and please let us know how you did / what the issue was!

__________________
Grant Johnson
Seek, and ye shall find.
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Inspiring, Informing and Connecting travellers since 1997!
www.HorizonsUnlimited.com

You have to loosen the tensioner. It's a pain in the ass. And you have to re-tension it with a special torque wrench otherwise the tension is guesswork.

This guy seems to manage it. He winged it in his own words. With experience you can feel a correct tension.

https://www.youtube.com/watch?v=NoJyl0x02LI

It's not how I'd do it but I have the proper gear.

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Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

Hi everyone
I am happy to say I have got to the bottom of the Alternator drive belt problem .The belt I was trying to fit was a 4pk 592 elast belt supposedly the correct one for my 2003 1150 gs ( with a freewheel mechanism on the alternator pulley) I checked the No. both with the BMW parts supplier and a BMW dealer useing both reg No. and Vin No..After struggling for a few days ie keep going back to it I gave up and fitted the older Poly V belt as for the older system 4pk 611 This fitted straight on no trouble at all ( I still suspect that the origional 4pk592 was wrongly sizes so when I have chance I will take it to the BMW dealer and compare it ). But several people on various forums pointed out, why struggle as the correct "elast " belt is a pig to fit, just fit the old poly v belt adjust it the old way ie torque to 8NM and readjust next 6000 mile service and I will change it at 24000 mile instead of the new spec 36000 mile .
So in conclusion while I do like to service everything exactly as it is supposed to be I am afraid for my sanity sake I reverted to the old method .
Just for information sake any one purchasing the 4pk 611 poly vbelt it is readilly available at auto stores as it is the standard belt fitted to Hyundai accent / getz cars .
Regards Mike