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)
- Disarm security system. Remove main fuse. See Service Procedures → 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 2. 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 3. 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
Service belt tension specification is for belts with more than 1,600 km (1000 mi). Set belt to new belt tension specification if the belt has less than 1,600 km (1000 mi).
Table 1. Drive Belt Deflection
MODEL | DEFLECTION (1) | |
|---|---|---|
in | mm | |
Service belt tension | 1/2-9/16 | 12.7-14.2 |
New belt tension | 3/16-1/2 | 4.7-12.7 |
(1) Deflection measured at 10 lb (4.5 kg) 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 | Drive belt |
| 2 | Deflection graduations (Approx: 1.5 mm (1/16-in) |
Figure 2. Belt Deflection Window
| 1 | Transmission sprocket |
| 2 | Rear wheel sprocket |
| 3 | 10 lb (4.5 kg) of force |
| 4 | Amount of deflection |
Figure 3. Checking Belt Deflection