Special Tools

Description	Part Number	Qty.
BELT TENSION GAUGE	HD-35381-A	1

NOTE

Always use BELT TENSION GAUGE (Part Number:HD-35381-A) to measure belt deflection. Failure to use tension gauge may cause under-tensioned belts. Loose belts can fail due to "ratcheting" (jumping a tooth) which causes tensile cord crimping and breakage.

1.	Set motorcycle upright. See SCHEDULED MAINTENANCE → Preparing the Motorcycle for Maintenance.
2.	Put transmission in neutral.
3.	Allow vehicle to cool.
4.	Remove all load (rider, passenger and cargo).
	WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
5.	Remove main fuse. See Service Procedures → Fuses and Relays.
6.	See Figure 1. Slide O-ring (4) to 0 kg (0 lb) mark (3).
7.	Fit belt cradle (2) against bottom of drive belt and align with belt deflection window.
8.	Press up on knob (6) until O-ring slides down to 4.5 kg (10 lb) mark (5) and hold steady. NOTE Each deflection graduation is 1.59 mm (0.0625 in).
9.	See Figure 2. Measure belt deflection through window.
10.	Compare measurement to specifications. Refer to Table 1.
11.	Adjust belt if necessary. See a Harley-Davidson dealer.
12.	Inspect rear sprocket. Replace rear sprocket if major tooth damage or loss of chrome exists. See a Harley-Davidson dealer.
13.	Install main fuse.

Table 1. Belt Deflection Specifications*

MODELS	mm	in
XG500	12.7-15.9	0.50-0.62
XG750	12.7-15.9	0.50-0.62
XG750A	12.7-15.9	0.50-0.62
* Deflection measured at 4.5 kg (10 lb) tension.

1	Belt tension gauge
2	Belt cradle
3	0 kg (0 lbs) mark
4	O-ring
5	4.5 kg (10 lbs) mark
6	Knob

Figure 1. Belt Tension Gauge

1	Drive belt
2	Deflection graduations (Approx: 1.5 mm (1/16-in)

Figure 2. Belt Deflection Window