How to Change a Belt Drive on a 2002 Harley Davidson Sportster

Print this articleThe 2002 Sportster models used the same polymer drive belts found on the rest of Harley-Davidson's newer machines, providing the rider with several thousand miles of quiet, nearly maintenance-free rides. Drive belts do have a disadvantage however, especially when replacing a worn belt -- unlike a traditional drive chain, which can be separated and joined after installation, the belt must be removed and installed as a whole. The job calls for basic hand tools and a motorcycle jack, but will take several hours to complete.

Related Searches:Difficulty:ModerateInstructions Things You'll Need5/16-, 1/2-, 5/16-, 15/16- and 3/4-inch socketsSocket wrenches1/2-, 7/16- and 3/4-inch open-end wrenches1/4- and 3/16-inch Allen wrenchesMotorcycle jackRatcheting tie-down strapsNeedle-nose pliersRubber malletBungee cords9/16-inch deep wall socketBelt tension gaugeTorque wrenchSuggest Edits1

Loosen the rear muffler clamp, using a 5/16-inch socket and a socket wrench. Unscrew the mounting nut from the back of the rear muffler, using a 1/2-inch socket. Pull the rear muffler off the exhaust pipes.

2

Loosen the brake rod lock nut from the rear brake master cylinder, located below the right front foot peg, using a 1/2-inch open-end wrench. Unscrew the brake rod from the rear brake pedal, using a 7/16-inch open-end wrench.

3

Unscrew the rear brake hose clips from the swingarm, using a 5/16-inch socket and a socket wrench. Unscrew the rear brake master cylinder mounting bolts with a 1/4-inch Allen wrench. Hang the master cylinder from the rear fender supports, using a bungee cord.

4

Unscrew the front sprocket cover from the right side of the transmission, using a 3/16-inch Allen wrench. Pull the sprocket cover away from the transmission.

5

Pull the cotter pin out from the left side of the rear axle, using needle-nose pliers. Loosen the rear axle nut, using a 15/16-inch socket and a long-handled socket wrench.

6

Lift the motorcycle off the ground with a motorcycle jack placed below the engine. Tie the motorcycle's handlebars to the jack's anchor points with ratcheting tie-down straps to prevent it from tipping over.

7

Tap the rear axle out from the right side of the rear wheel. Lift the rear brake caliper out from in-between the right side of the rear wheel and the swingarm. Hang the caliper from the rear fender support with a bungee cord. Roll the rear wheel forward slightly and pull the drive belt off the rear wheel sprocket. Roll the wheel away from the motorcycle.

8

Hold the lower right shock absorber mounting bolt steady with a 3/4-inch open-end wrench. Unscrew the shock lower absorber nut, using a 3/4-inch socket and a socket wrench. Pivot the shock absorber up and away from the motorcycle's swingarm. Hold the shock absorber in place with a bungee cord.

9

Unscrew the belt guards from the right side of the swingarm, using a 1/4-inch Allen wrench and a 1/2-inch socket and a socket wrench. Pull the drive belt off the front sprocket and away from the motorcycle.

10

Loosen the belt tensioner lock nuts on both sides of the swingarm, using a 9/16-inch open-end wrench. Turn the tensioner bolts clockwise until the tensioners are set at their loosest position, using a 9/16-inch deep wall socket and a socket wrench. Roll the rear wheel into the swingarm, as far forward as possible.

11

Slip the new drive belt over the rear wheel sprocket and the front sprocket. Roll the wheel back and place the rear brake caliper, between the right side of the wheel and the swingarm. Push the rear axle through the swingarm and the rear wheel. Loosely screw the rear axle nut into place with a 15/16-inch socket and a socket wrench.

12

Turn both belt tensioners counter-clockwise evenly, using a 9/16-inch deep wall socket and a socket wrench to tighten the drive belt. Check the tension at the bottom strand of the belt, using a belt tension gauge. Stop tightening the belt when the belt has range of movement between 3/16- to 5/8-inch while applying 10 pounds of pressure with the belt tension gauge.

13

Measure the distance between the center of the rear axle on both sides of the rear wheel in relation to the ends of the swingarm, using a ruler or tape measure. Loosen the tensioner with the higher measurement, if the measurements are uneven. Tighten the rear axle nut to 56 foot-pounds, using a 15/16-inch socket and a socket wrench, once both tensioners are evenly aligned. Slip a new cotter pin into the left side of the rear axle, then bend the pin's legs out with needle-nose pliers.

14

Reinstall the lower right shock absorber bolt and nut, using a 3/4-inch open-end wrench and a 3/4-inch socket. Tighten the nut to 50 foot-pounds with a 3/4-inch socket and a torque wrench.

15

Reinstall the belt guards, using a 1/4-inch Allen wrench. Reinstall the front sprocket cover onto the transmission with a 3/16-inch Allen wrench.

16

Reinstall the rear brake master cylinder onto the motorcycle, using a 1/4-inch Allen wrench. Tighten the bolts to 20 foot-pounds, using a torque wrench. Screw the brake rod into the rear brake pedal, using a 7/16-inch open-end wrench. Tighten the brake rod lock nut with a 1/2-inch open-end wrench.

17

Slip the rear muffler onto the exhaust pipes, then tighten the muffler mounting nut to 15 foot-pounds with a torque wrench. Tighten the muffler clamp with a 5/16-inch socket and a socket wrench.

18

Lower the motorcycle to the floor and park it on its side stand.

References"Harley-Davidson Service Manual: Sportster Models"; Harley-Davidson Motor Co.; 2002Read Next:

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