General
The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.
Refer to Maintenance Scheduling → Regular Service Intervals → Regular Service Intervals: 2005 Sportster Models. Belt tension is set at the factory and should be checked after the first 1000 miles (1600 kilometers) and at proper intervals thereafter.
Table 1. Belt Deflection: 2005 Sportster Models
MODELS
MILLIMETERS
INCHES
883C, 1200C
6.5-7.9
1/4-5/16
883, 883L, 883R, 1200R
9.5-11.1
3/8-7/16
Checking Deflection
See Figure 1. With the rear wheel on the ground and one rider sitting on the motorcycle, use the BELT TENSION GAUGE (Part No. HD-35381) to apply 10 lbs. (4.5 kg) of force at the midpoint of the bottom belt strand. Belt deflection for 883 and 1200 Custom models should be 1/4-5/16 in. (6.5-7.9 mm). Belt deflection for 883 standard and 1200 Roadster models should be 3/8-7/16 in. (9.5-11.1 mm). If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the instructions given in the applicable Service Manual.
WARNING
Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)
Check rear brake caliper position on rear brake disc. Disc should run true within brake caliper.
1Transmission sprocket
2Rear wheel sprocket
3Force of 4.5 kg (10 lbs)
4Deflection (refer to table)
Figure 1. Check Belt Deflection: Sportster Models