CHROME LOWER BELT GUARD KIT
J019852007-11-12
GENERAL
Kit Number
60484-01A, 60484-01B, 60493-04, 60493-04A, 60839-07
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Tools and Supplies Required
A Belt Tension Gauge (Part Number HD-35381A) will aid in the installation of this kit, and is available from a Harley-Davidson Dealer.
NOTE
Setting belt tension without using a Belt Tension Gauge can lead to a loose belt. A loose belt can fail due to tensile cord damage caused by ratcheting (jumping a tooth).
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
A Service Manual for your model motorcycle is available from a Harley-Davidson Dealer.
Kit Contents
Table 1. Kit Contents
Description (Quantity) | Part Number |
|---|---|
Belt guard, lower (chrome) | Not sold separately |
Bushing, lower belt guard front mount | 67633-01 |
INSTALLATION
NOTE
The Chrome Lower Belt Guard (debris deflector) in this kit is not equipped with a window for reading belt tension, as found on the original equipment (O.E.) lower guard. The O.E. lower guard should be retained if possible, as an aid to future belt adjustments.
Be sure to read and save the directions covering belt adjustment at the end of these instructions.
| 1. | Check the rear belt deflection per the instructions in the Service Manual, and adjust the belt tension as necessary. | 
Figure 1. Remove Lower Belt Guard Rear Fasteners | ||||||
| 2. | See Figure 1. Remove the socket head screw and washer (1) securing the rear of the lower belt guard (2) to the rear fork (swingarm). Save the fasteners for re-installation. | |||||||
| 3. | Push the lower belt guard (2) toward the rear of the vehicle (3) to remove it from the front mount rubber bushing (see Figure 2 , Item 1). It may be necessary to work the lower guard up and down slightly until it detaches from the bushing. | 
Figure 2. Remove Lower Belt Guard Front Mount | ||||||
| 4. | Remove the hex head screw and washer (2) securing the bushing to the rear fork. Discard the bushing, but save the screw and washer for re-installation. | |||||||
| 5. | Obtain the new front lower belt guard mount bushing from the kit. Using the hex head screw and washer saved in Step 4, install the new bushing to the rear fork. Tighten the screw to 6–10 N·m (4.4–7.4 ft-lbs). | |||||||
| 6. | Obtain the new chrome lower belt guard from the kit. Position the lower guard over the belt, and slide the cutout at the front of the guard around the rubber bushing. Push the lower guard toward the front of the vehicle until the cutout is completely secured ("sandwiched") between the bushing flanges. | |||||||
| 7. | See Figure 1. Install the socket head screw and washer saved in Step 2 to secure the rear of the belt guard to the rear fork. Tighten the screw to 6–10 N·m (4.4–7.4 ft-lbs). | |||||||
| 8. | READ AND SAVE the following instructions covering new procedures for determining and adjusting belt deflection. |
Determining and Adjusting Belt Deflection
NOTE
Because the Chrome Lower Belt Guard is not equipped with a window for reading belt tension, use one of the two following methods when adjusting the belt to determine the correct amount of belt deflection (free play, or up-and-down movement).
| 1. | Method 1, using saved O.E. lower belt guard: a. See Figure 3. Remove the chrome lower belt guard, and re-install the O.E. lower belt guard. b. Use a Belt Tension Gauge (HD-35381A) (2), and follow the instructions in the Service Manual to adjust the belt through the adjustment window (1) in the lower guard. c. After proper belt deflection is achieved, remove the O.E. lower belt guard, and re-install the chrome guard per the INSTALLATION instructions on the other side of this sheet. | 
Figure 3. Determining Belt Deflection With O.E. Guard | ||||
| 2. | Method 2, O.E. lower belt guard unavailable: a. Remove the chrome lower belt guard. b. See Figure 4. Position the motorcycle standing straight upright, with a COLD engine, the transmission in NEUTRAL and NO RIDER sitting on the bike. Place a ruler (1), standing upright on the ground halfway between the transmission sprocket and rear sprocket, and resting against the straight side surface of the belt. c. Use a Belt Tension Gauge (HD 35381A) to apply 4.5 kg (10 lbs) of upward force to the lower section of the belt. The amount of upward belt deflection (2) measured with the ruler should be as indicated under REAR BELT DEFLECTION in the Service Manual for your year and model motorcycle. d. Follow the instructions in the Service Manual and perform the deflection adjustment. e. After proper belt deflection is achieved, re-install the chrome guard per the INSTALLATION instructions on the other side of this sheet. |
| 1 | Ruler |
| 2 | Deflection range |
Figure 4. Determining Belt Deflection With Ruler