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:
- 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)
| 1. | Disarm security system. Remove main fuse. See Service Procedures → Fuses. | |
| 2. | Shift transmission to neutral. NOTE When adjusting a new belt, rotate rear wheel a few revolutions prior to setting the tension. | |
| 3. | See Figure 1. Measure belt deflection using: Special Tool: BELT TENSION GAUGE (HD-35381-A) a. Slide O-ring (4) to zero mark (3). b. Models equipped with belt deflection window: Fit belt cradle (2) against bottom of drive belt in line with belt deflection window. c. All other models: Fit belt cradle (2) against bottom of drive belt halfway between drive pulleys. d. Press upward on knob (6) until O-ring slides down to 4.54 kg (10 lb) mark (5) and hold steady. | |
| 4. | Measure belt deflection: a. 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) b. All other models: See Figure 2. Measure amount of deflection (4) while holding gauge steady. | |
| 5. | NOTE Set to the lower (tightest) specification if the belt has less than 1,600 km (1000 mi). | |
| 6. | Install main fuse. |
Table 1. Belt Deflection
MODELS | in | mm |
|---|---|---|
All models | 3/8-7/16 | 9.5-11.1 |
| 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