Belt Drive Question
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Stage IV
Joined: Sep 2015
Posts: 4
Likes: 0
From: Berkeley
Belt Drive Question
Hi All,
I could use some help and advice. I recently broke the final drive belt on my 93 sportster 883 xlh deluxe. I haven't done much wrenching since I was a kid ... 45 years ago ... but I am trying to do all I can on my sportster. I bought a factory service manual and a motorcycle lift and I think I have a good array of tools.
So my question is: how hard is this for a beginner mechanic to do? I can read the directions pretty well, but I would hate to screw something up due to inexperience that could compromise my safety ... or cause more belt breakage.
I see a tension gauge advertised with a tension adjusting tool for $25.00. Is this helpful or necessary?
But mostly I would like opinions on whether removing the tire and installing a new belt is to much of a job for a beginner working from a manual. How easy is it to screw something up that would compromise safety or cause ongoing problems?
Thanks in advance. Last time I posted here I got a great response and was able to fix my problem. So thanks again ...
Ride Safe.
Dave
I could use some help and advice. I recently broke the final drive belt on my 93 sportster 883 xlh deluxe. I haven't done much wrenching since I was a kid ... 45 years ago ... but I am trying to do all I can on my sportster. I bought a factory service manual and a motorcycle lift and I think I have a good array of tools.
So my question is: how hard is this for a beginner mechanic to do? I can read the directions pretty well, but I would hate to screw something up due to inexperience that could compromise my safety ... or cause more belt breakage.
I see a tension gauge advertised with a tension adjusting tool for $25.00. Is this helpful or necessary?
But mostly I would like opinions on whether removing the tire and installing a new belt is to much of a job for a beginner working from a manual. How easy is it to screw something up that would compromise safety or cause ongoing problems?
Thanks in advance. Last time I posted here I got a great response and was able to fix my problem. So thanks again ...
Ride Safe.
Dave
Road Master
Joined: Apr 2014
Posts: 841
Likes: 58
From: Yakima
It's not too bad. The tension tool is really helpful for getting the new belt tensioned correctly. Also you'll want a tool for aligning the back tire. I made one out of a coat hanger.
Look up Delboy garage on YouTube. He's got some pretty awesome instructional videos. Including tensioning the belt and aligning the rear tire.
Look up Delboy garage on YouTube. He's got some pretty awesome instructional videos. Including tensioning the belt and aligning the rear tire.
Road Master
Joined: Apr 2014
Posts: 841
Likes: 58
From: Yakima
Originally Posted by gearhead1937
I broke one on my '05 and I didn't have to remove the tire.
Club Member
Joined: Feb 2007
Posts: 16,320
Likes: 306
From: Boynton Beach, FloriDuh
You don't really need a belt tension gauge. To check the tension, grab the lower part of the belt half way between the two pulleys with your thumb and forefinger. I like to reach in from behind the belt when I grab it so that the thumb is on the bottom of the belt and your fingers are point towards you. Using just the thumb and forefinger, twist the belt as far as you can pushing upwards with your thumb. The belt should twist between a minimum of 45* (less is too tight) and a maximum of 90* (more is too loose), right in the middle is perfect.
I've used this method for over 100,000 miles and never had a problem.
This is also a quick and easy check you can do if you've let someone else change your rear tire, before you ride off into the sunset with a mis-adjusted belt.
I've used this method for over 100,000 miles and never had a problem.
This is also a quick and easy check you can do if you've let someone else change your rear tire, before you ride off into the sunset with a mis-adjusted belt.
Last edited by cHarley; Oct 11, 2015 at 12:41 PM.
Outstanding HDF Member
Joined: Feb 2015
Posts: 2,414
Likes: 433
From: Arkansas
I broke a belt on my 01 XLH883 and it wasn't too bad to fix, however there is a proper tension check using the tension check tool listed in the service manual. To be on the safe side I would go with those instructions and get the tension check tool (10lbs of force is hard to tell with just your finger). I have both upper and lower belt guards in place which make it more of a PITA to install but it is still fairly easy, you just need to loosen the rear wheel alignment to full and pull the rear axle out enough to get the belt through, just don't forget to put the spacer back in when reinserting the rear axle. Use the coat hangar trick as indicated above and your rear wheel alignment should be correct. Front sprocket cover was the only real issue as you have to remove the rear exhaust pipe and rear master cylinder to remove the cover. The whole job took me about an hour by myself to do. Remember to check your torque values as you don't want to strip any bolts or have them too loose. And one more thing, ensure that you have the gasket for the exhaust before you begin, they deteriorate and break up when removed.
Cruiser
Joined: Apr 2013
Posts: 207
Likes: 5
From: Iowa
I took my top belt gaurd off. Put the bike on the lift. Removed the right shock, front pully gaurd. Loosened the tire and slide it forward... Poof, new belt went right on. Readjust tension and ride. 30 min job.
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Road Master
Joined: Apr 2014
Posts: 841
Likes: 58
From: Yakima
Originally Posted by gearhead1937
I took my top belt gaurd off. Put the bike on the lift. Removed the right shock, front pully gaurd. Loosened the tire and slide it forward... Poof, new belt went right on. Readjust tension and ride. 30 min job.
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Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
Unless you have calibrated fingers, buy that tension tool! A 300 pound weight lifter is likely to be a darned sight stronger than a 100 pound lass FFS, so forget about twisting. The main cause of broken belts (yours may just be very old) is incorrect belt tension, so set it right.
Club Member
Joined: Feb 2007
Posts: 16,320
Likes: 306
From: Boynton Beach, FloriDuh
Unless you have calibrated fingers, buy that tension tool! A 300 pound weight lifter is likely to be a darned sight stronger than a 100 pound lass FFS, so forget about twisting. The main cause of broken belts (yours may just be very old) is incorrect belt tension, so set it right.
