Tools and Materials:
Socket set
Wrench set
Pry bar
Flat-head screwdriver
Needle-nose pliers
Jack
Safety glasses
New drive belt
Replacement belt tensioner (if necessary)
Instructions:
1. Prepare the Motorcycle:
- Put on safety glasses to protect your eyes.
- Park your Harley Softail on a level surface.
- Turn off the engine and let it cool down completely.
- Engage the parking brake and put the motorcycle in neutral gear.
2. Lift the Rear of the Motorcycle:
- Use a jack to lift the rear of the motorcycle off the ground.
- Make sure the motorcycle is securely supported before you begin working on it.
3. Locate the Drive Belt:
- The drive belt is located on the right side of the motorcycle, running from the front pulley to the rear pulley.
4. Remove the Belt Guard:
- Locate the belt guard covering the drive belt. You may find two guards covering both the primary drive and drive belt; sometimes, there is only one guard.
- Use a wrench or socket set to loosen and remove the belt guard mounting bolts.
- Set aside the belt guard to access the drive belt.
5. Pry the Idler Pulley Arm:
- Use a pry bar or flat-head screwdriver to pry the idler pulley arm away from the drive belt.
- Keep the idler pulley arm disengaged to release tension on the drive belt.
6. Remove the Drive Belt:
- Slide the drive belt off the front and rear pulleys.
- Be careful not to drop the drive belt or any of its components.
7. Replacing the Tensioner (Optional):
- If you notice cracks or damage to your tensioner, this is an excellent opportunity to replace it with a new one.
- Refer to your Softail's service manual for specific steps on replacing the tensioner.
8. Install the New Drive Belt:
- Align the new drive belt with the front and rear pulleys.
- Ensure the belt is properly seated on both pulleys.
9. Reattach the Idler Pulley Arm:
- Release the pry bar or flat-head screwdriver from the idler pulley arm.
- Allow the idler pulley arm to return to its original position, applying tension to the drive belt.
10. Adjust Belt Tension:
- Follow the recommended belt tension specifications for your specific Softail model.
- Use a wrench to adjust the tensioner and ensure the drive belt has the correct amount of slack.
11. Reinstall the Belt Guard:
- Place the belt guard back on the motorcycle and secure it with the mounting bolts.
12. Lower the Motorcycle:
- Carefully lower the motorcycle using the jack.
- Ensure the motorcycle is stable and secure before removing the jack.
13. Test Ride:
- Take the motorcycle for a short test ride to ensure the drive belt is functioning correctly.
Remember to consult your Harley Softail's service manual for specific instructions and torque specifications related to your motorcycle model. If you are unsure about any part of this process, it's best to seek professional assistance from a qualified mechanic.
