Special Tools
DescriptionPart NumberQty.
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.
Gauging Deflection
Check belt deflection at the loosest spot in the belt with the transmission in neutral and the motorcycle at ambient temperature.
  1. With the motorcycle unladen and resting on its jiffy stand, fit the BELT TENSION GAUGE (Part Number:HD-35381-A) on the belt.
    1. XL Models: See Figure 1. Position the gauge half-way between the transmission and rear wheel sprockets.
    2. XR 1200X: See Figure 2. Fit the tension gauge half-way between the idler wheel and rear sprocket.
  2. With the BELT TENSION GAUGE set to 0 kg (0 lb), note the current belt position.
    1. XL Models: See Figure 3. Note the belt position according to the graduations on the belt deflection window located on the drive belt guard.
    2. XR 1200X: See Figure 4. Note the belt position according to the graduations on the front of the debris deflector.
  3. 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.
  4. Compare the deflection to specifications. Refer to Table 1.
  5. 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
MODELS
in
mm
XL 883R
9/16-5/8
14.3-15.9
Other XL models
1/4-5/16
6.4-7.9
XR 1200X
1/4-3/8
6.4-9.5
1Transmission sprocket
2Rear wheel sprocket
3Force of 10 lb (4.5 kg)
4Deflection (refer to table)
Figure 1. Gauging Belt Deflection: XL Models
1Transmission sprocket
2Rear wheel sprocket
3Force of 10 lb (4.5 kg)
4Deflection (refer to table)
5Idler wheel
Figure 2. Gauging Belt Deflection: XR 1200X
1Drive belt
2Deflection graduations 1/8 in (3.2 mm) apart
Figure 3. Belt Deflection Window: XL Models
1Drive belt
2Deflection graduations 1/8 in (3.2 mm) apart
Figure 4. Belt Deflection: XR 1200X