Broken Drive Belt
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Road Master
Joined: Aug 2005
Posts: 1,213
Likes: 0
From: Cape Coral, Fl.
We ran into some trouble putting the bike back together. We ordered the OEM belt, it arrived on time, put the front part back together and was ready to install the rear wheel. The OEM belt we bought is 1.5 inches wide and wont fit the rear pulley. We should have measured the original belt... :-(
We went with what the catalog says was the right belt. My original belt was 1.25" wide. Whats up with this? All we can figure out is the rear pulley must have been changed before I bought the bike.
Our delima... take the OEM belt back off and re-order a 1.25" belt and use the original pully that came off the bike, or try to find a 1.5" rear pulley? The indy is just shaking his head over this. Appologized up and down, but is leaving the decision up to me. Says he wont charge to take the OEM belt back off, because he should have measured it to begin with. This guy is a friend and I don't want him taking a beating over this.
To top it off, I had planned to ride with the FLA CREW today up to Solomons Castle, and all of a sudden I am not going to have a ride. Indy called his boss, told him the story, boss says I can take their Road King for the weekend.
Well I gotta tell ya, Im IMPRESSED with my luck to have such a great shop to do my work. l want to say thanks to "Big R Customs" here in cape coral, fl. Great bunch of people to deal with.
We went with what the catalog says was the right belt. My original belt was 1.25" wide. Whats up with this? All we can figure out is the rear pulley must have been changed before I bought the bike.
Our delima... take the OEM belt back off and re-order a 1.25" belt and use the original pully that came off the bike, or try to find a 1.5" rear pulley? The indy is just shaking his head over this. Appologized up and down, but is leaving the decision up to me. Says he wont charge to take the OEM belt back off, because he should have measured it to begin with. This guy is a friend and I don't want him taking a beating over this.
To top it off, I had planned to ride with the FLA CREW today up to Solomons Castle, and all of a sudden I am not going to have a ride. Indy called his boss, told him the story, boss says I can take their Road King for the weekend.
Well I gotta tell ya, Im IMPRESSED with my luck to have such a great shop to do my work. l want to say thanks to "Big R Customs" here in cape coral, fl. Great bunch of people to deal with.
Last edited by Araba Shriner; Jun 20, 2009 at 06:50 AM.
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
FWIW, a rock puncture near the center of the belt can be fixed. This happened on my old RK in 1998 and I fixed it like this:
1. Clean rock particles from puncture.
2. Apply some JB Weld (epoxy) in the hole, smoothing it out on the outer area (smooth side) and removing the excess. Make sure it completely fills the puncture hole.
3. Apply some plastic wrap on the inner area (toothed side) and roll the affected part of the belt over the pulley.
Doing this makes the epoxy form to the shape of the belt and pulley.
4. Leave it in this position overnight or as long as specified in the directions for curing.
My old RK still has the original repaired belt on the bike today at 120k miles and the repair looks the same as it did when applied. I'm told that a puncture toward the edge of the belt may not be repairable, at least for the long term. In any case I would inspect the belt every time you clean the rear wheel, even if there are no repairs to check. You'll want to deal with a repair sooner rather than later.
1. Clean rock particles from puncture.
2. Apply some JB Weld (epoxy) in the hole, smoothing it out on the outer area (smooth side) and removing the excess. Make sure it completely fills the puncture hole.
3. Apply some plastic wrap on the inner area (toothed side) and roll the affected part of the belt over the pulley.
Doing this makes the epoxy form to the shape of the belt and pulley.
4. Leave it in this position overnight or as long as specified in the directions for curing.
My old RK still has the original repaired belt on the bike today at 120k miles and the repair looks the same as it did when applied. I'm told that a puncture toward the edge of the belt may not be repairable, at least for the long term. In any case I would inspect the belt every time you clean the rear wheel, even if there are no repairs to check. You'll want to deal with a repair sooner rather than later.
Tourer
Joined: Sep 2007
Posts: 298
Likes: 0
From: Alden, NY
I haven't done one on a touring model but I put a new belt on my Heritage Springer last January. If you are handy and have a Service Manual and a motorcycle jack, you can do it. If a tech can do it in 3 hours, God Bless him. I probably had about 10 hours in it but there is a lot more room to remove things, such as the starter on a touring model. My belt was about $180, primary gaskets and oil about another 90. You will need to either buy or borrow the appropriate tool to jam the primary chain/compensating and clutch sprockets to break the bolts loose and you'll need a torque wrench. Lining up the rear wheel and the new belt is critical to its longevity too.
Road Warrior
Joined: Apr 2009
Posts: 1,800
Likes: 414
From: Ellensburg, WA
Bike drive belts are not expensive (relatively speaking).. My winter passion is snowmobiles. No labor involved in the change, but each belt is $145. Most seasons I go through 2 and the wife goes through 1. Gotta love your hobbies.
Where mine broke, there were fresh threads dangling. But here's the kicker: It was only 25% of the width of the band, (meaning that 3/4 of it was already tore, from who knows how long back.) I can't believe I was riding like that. I know my guardian angel must have been holding it together as long as he could.
Road Master
Joined: May 2005
Posts: 1,121
Likes: 3
From: Mass.
So, on my '05 RG at 25,000 miles Harley replaced the belt under warrantee due to "unusual wear", I paid for a new rear pulley. On the way home the new belt snapped, about 24 miles on it. LOL! As I rolled to a stop a friend coming home from work stopped. I called the dealer and they came got the bike and replaced the belt (again). Fast forward 45000 miles and we have just replaced the belt and pulleys again. The cogs were starting to separate from the belt.
It should be about a $500 job give or take depending on how many pulleys are replaced. That $1275 price had better include a lot of extra stuff or someone got seriously raped.
It should be about a $500 job give or take depending on how many pulleys are replaced. That $1275 price had better include a lot of extra stuff or someone got seriously raped.
Seasoned HDF Member
Joined: Nov 2010
Posts: 17,548
Likes: 7,197
From: Oxford, Nc
Well that's nice that they loaned you a bike because somebody read the catalog wrong.
The 1 1/2" belt fits 2003 and earlier baggers. 2004 had 1 1/4" carbon fiber ( stronger) belt. Either the catalog was wrong (?), or the Indy read it wrong. 05 never had a 1 1/2" belt and your skinny pulley is stock.
The 1 1/2" belt fits 2003 and earlier baggers. 2004 had 1 1/4" carbon fiber ( stronger) belt. Either the catalog was wrong (?), or the Indy read it wrong. 05 never had a 1 1/2" belt and your skinny pulley is stock.
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