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.
Check deflection:
- As part of pre-ride inspection.
- At every scheduled service interval.
- With transmission in neutral.
- With motorcycle at ambient temperature.
- With motorcycle upright or on jiffy stand with rear wheel on the ground.
- With the vehicle unladen: no rider, no luggage and empty saddlebags.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Disarm security system. Remove main fuse. See Maintenance and Lubrication → Fuses.
- Shift transmission to neutral.
- See Figure 1. Measure belt deflection using BELT TENSION GAUGE (Part Number:HD-35381-A):
- Slide O-ring (4) to zero mark (3).
- Models equipped with belt deflection window: Fit belt cradle (2) against bottom of drive belt in line with belt deflection window.
- All other models: Fit belt cradle (2) against bottom of drive belt halfway between drive pulleys.
- Press upward on knob (6) until O-ring slides down to 4.54 kg (10 lb) mark (5) and hold steady.
- Measure belt deflection:
- Models equipped with belt deflection window: See Figure 3. Measure belt deflection as viewed through belt deflection viewing window while holding gauge steady. Each deflection graduation is approximately 1.6 mm (1/16 in).
- All other models: See Figure 2. Measure amount of deflection (4) while holding gauge steady.
- Compare with specifications. Refer to Table 1. If not within specifications, see a Harley-Davidson dealer.
- Install main fuse.
NOTE
When adjusting a new belt, rotate rear wheel a few revolutions prior to setting the tension.
NOTE
Set to the lower (tightest) specification if the belt has less than 1,600 km (1000 mi).
Table 1. Belt Deflection Specifications*
MODELS | in | mm |
|---|---|---|
All models | 1/4-5/16 | 6.4-7.9 |
* Deflection measured at 4.5 kg (10 lb) tension. | ||
| 1 | Belt tension gauge |
| 2 | Belt cradle |
| 3 | 0 lb (0 kg) mark |
| 4 | O-ring |
| 5 | 10 lb (4.5 kg) mark |
| 6 | Knob |
Figure 1. Belt Tension Gauge
| 1 | Transmission sprocket |
| 2 | Rear wheel sprocket |
| 3 | 10 lb (4.5 kg) of force |
| 4 | Amount of deflection |
Figure 2. Checking Belt Deflection
| 1 | Drive belt |
| 2 | Deflection graduations (Approx: 1.5 mm (1/16-in) |
Figure 3. Belt Deflection Window