Special Tools

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

General

The inner tooth surface of the secondary belt has a thin coating of polyethylene lubricant. During initial operation, this coating will wear off as it is burnished into the belt fabric. This is a normal condition and not an indication of belt wear.

Belt tension is set at the factory and should be checked after the first 1,600 km (1000 mi), at scheduled maintenance intervals, and after a hard ride.

Gauging Deflection

Check belt deflection at the loosest spot in the belt with the transmission in neutral and the motorcycle at ambient temperature.

With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE (Part Number:HD-35381-A) on the belt.
1. See Figure 4. On XR 1200 model, fit BELT TENSION GAUGE half-way between the idler wheel and rear sprocket.
2. See Figure 3. On all other models, position the gauge half-way between the transmission and rear wheel sprockets.
With the BELT TENSION GAUGE set to 0 kg (0 lb), note the current belt position.
1. See Figure 2. On XR 1200 model, note the belt position according to the graduations on the front of the debris deflector.
2. See Figure 1. On all other models, note the belt position according to the graduations on the belt deflection window located on the rear drive belt guard.
Using the BELT TENSION GAUGE, apply 4.5 kg (10 lb) of force to the bottom belt. Count the number of graduations between the original belt position and after applying the force. Multiply this number by 3.2 mm (⅛ in) to determine the deflection.
Refer to Table 1 for the recommended deflection. If belt tension adjustment is necessary, see a Harley-Davidson dealer or follow the belt deflection adjustment procedure in the Service Manual.

WARNING

Be sure wheel and brake caliper are aligned. Riding with a misaligned wheel or brake caliper can cause the brake disc to bind and lead to loss of control, which could result in death or serious injury. (00050a)

NOTE

When gauging deflection, check the rear brake caliper position on rear brake disc. Disc should run true within brake caliper.

Table 1. Belt Deflection: Sportster Models

MODELS	INCHES	MILLIMETERS
XL 883C, XL 883L, XL 1200C, XL 1200L, XL 1200N	1/4-5/16	6.4-7.9
XL 883, XL 883R, XL 1200R	9/16-5/8	14.3-15.9
XR 1200	1/4-3/8	6.4-9.5

1	Rear drive belt
2	Deflection graduations 1/8 in. (3.2 mm) apart

Figure 1. Belt Deflection Window (typical)

1	Rear drive belt
2	Deflection graduations 1/8 in. (3.2 mm) apart

Figure 2. Belt Deflection: XR 1200 Model

1	Transmission sprocket
2	Rear wheel sprocket
3	Force of 10 lbs (4.5 kg)
4	Deflection (refer to table)

Figure 3. Gauging Belt Deflection: Sportster XL Models

1	Transmission sprocket
2	Rear wheel sprocket
3	Force of 10 lbs (4.5 kg)
4	Deflection (refer to table)
5	Idler wheel

Figure 4. Gauging Belt Deflection: XR 1200 Model