Special Tools
| Description | Part Number | Qty. |
|---|---|---|
| BELT TENSION GAUGE | HD-35381-A | 1 |
NOTE
Always use the required special tool 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 belt 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 and no luggage.
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1. | Deactivate electrical system. See SECURITY SYSTEM → Disconnecting Power. | |
| 2. | See Figure 1. Remove lower belt guard. a. Remove screws (1) and lower belt guard (2). | |
| 3. | See Figure 2. Measure belt deflection using: Special Tool: BELT TENSION GAUGE (HD-35381-A) a. Slide O-ring (4) to zero mark (3). b. Fit belt cradle (2) against bottom of drive belt halfway between drive pulleys. c. Press upward on knob (6) until O-ring slides down to 4.54 kg (10 lb) mark (5) and hold steady. | |
| 4. | See Figure 3. Measure amount of deflection (4) while holding gauge steady. | |
| 5. | Compare with specifications. Refer to Table 1. If not within specifications, see a Harley-Davidson dealer. | |
| 6. | See Figure 1. Install lower belt guard. a. Place lower belt guard (2) in position. b. Install screws (1). Tighten. Torque: 5.5–7.5 N·m (48.7–66.4 in-lbs) Belt guard, lower, screw | |
| 7. | Reactivate electrical system. See SECURITY SYSTEM → Disconnecting Power. |
| 1 | Screw (2) |
| 2 | Lower belt guard |
Figure 1. Lower Belt Guard
Table 1. Drive Belt Deflection
MODEL | DEFLECTION |
|---|---|
Service belt tension(1) | 6.4–7.9 mm (0.25–0.31 in) |
(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 2. Belt Tension Gauge
| 1 | Transmission sprocket |
| 2 | Rear wheel sprocket |
| 3 | 10 lb (4.5 kg) of force |
| 4 | Amount of deflection |
Figure 3. Checking Belt Deflection