Special Tools
DescriptionPart NumberQty.
BELT TENSION GAUGE
HD-35381-A
1

General
Belt teeth are coated with polyethylene lubricant. Coating will wear off over time. This is not an indicator of belt wear.
Gauging Deflection
NOTE
  • When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run true within brake caliper.
  • Check belt deflection at the loosest spot in the belt with the transmission in neutral and the motorcycle at ambient temperature.
  1. With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE (Part Number:HD-35381-A) on the belt.
    1. XL Models: See Figure 1. Position the gauge half-way (1) between the transmission and rear wheel sprockets.
    2. XR 1200X: See Figure 2. Fit the tension gauge half-way (1) between the idler wheel and rear sprocket.
  2. With the BELT TENSION GAUGE set to 0 kg (0 lb), note the current belt position.
    1. XL Models: See Figure 1. View position through window (2) on drive belt guard.
    2. XR 1200X: See Figure 2. View position (2) on front of debris deflector (2).
  3. Using the BELT TENSION GAUGE, apply 4.5 kg (10 lb) of force to the bottom belt.
  4. Count the number of graduations (3) between the original belt position and after applying the force.
  5. Multiply this number by 3.2 mm (⅛ in) to determine the deflection. Compare the deflection to specifications. Refer to Table 1.
  6. If adjustment is necessary, see a Harley-Davidson dealer or follow the belt deflection adjustment procedure in the 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)
Table 1. Belt Deflection Specifications*
MODELS
in
mm
XL 883R
9/16-5/8
14.3-15.9
Other XL models
1/4-5/16
6.4-7.9
XR 1200X
1/4-3/8
6.4-9.5
* Deflection measured at 4.5 kg (10 lb) tension.
110 lb (4.5 kg)
2Deflection gauge
3Graduations 1/8 in (3.2 mm)
Figure 1. Belt Deflection: XL Models
110 lb (4.5 kg)
2Deflection gauge
3Graduations 1/8 in (3.2 mm)
Figure 2. Belt Deflection: XR 1200X