Drive Belt And Rear Sprocket - Buell 2002 P3 Service Manual

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DRIVE BELT AND REAR SPROCKET

GENERAL
Drive belt tension is not adjustable. Replace the belt and
sprocket if out of specification.
The drive belt and rear sprocket should be replaced:
●
Every 15,000 miles (24,000 km)
NOTE
When a drive belt is replaced for any reason other than stone
damage, it is recommended that the transmission and rear
sprockets also be replaced to increase the longevity of the
new drive belt. In the case of stone damage, inspect sprock-
ets for damage and replace as required.
CLEANING
Use only mild soap and water spray solution to clean drive
belt. Dry thoroughly. Do not immerse belt in solution.
INSPECTION
Checking Belt Deflection
NOTES:
Vehicle must be at room temperature and dry to obtain a cor-
rect measurement.
There are tight and loose spots during rear wheel rotation
that affect belt deflection. For a more precise measurement,
take three deflection readings, rotating the rear wheel
between measurements. Average the three readings for a
more precise measurement.
●
Deflection should be measured with the rear wheel on
the ground and a 160 lb. rider or equivalent weight sitting
on the motorcycle.
●
Maximum allowable deflection (measured with 10 lbs./
4.5 kg. of force) is 0.5 in. (12.7 mm) at the bottom strand.
See Figure 1-16. Using BELT TENSION GAUGE (Part No.
HD-35381), apply 10 lbs (4.5 kg) of force at the midpoint of
the belt's appropriate strand. The maximum allowable deflec-
tion is 0.5 in. (12.7 mm) at the bottom strand.
●
Replace belt and drive sprocket that exceed maximum
allowable deflection.
11 1
WARNING
Check alignment of the rear wheel and/or brake calipers
when servicing motorcycle. A misaligned rear wheel and/
or brake caliper could cause the rear brake disc to bind
resulting in loss of control and death or serious injury.
Rear Sprocket
1. See Figure 1-17. Inspect each tooth of rear sprocket for:
a. Major tooth damage.
b. Gouges caused by hard objects.
WARNING
a0040xox Top strand
10 lbs (4.5
kg) of force
Bottom strand deflection
Max. 0.5 in. (12.7 mm)
Figure 1-16. Measuring Belt Deflection
a0136x6x
Sprocket
Cover
Transmission
Sprocket
Figure 1-17. Drive Belt Assembly
2. Replace rear sprocket if major tooth damage exists.
Drive Belt
See Figure 1-18. Inspect drive belt for:
●
Cuts or unusual wear patterns.
●
Outside edge bevelling (8). Some bevelling is common,
but it indicates that sprockets are misaligned.
●
Outside ribbed surface for signs of stone puncture (7). If
cracks/damage exists near edge of belt, replace belt
immediately. Damage to center of belt will require belt
replacement eventually, but when cracks extend to edge
of belt, belt failure is imminent.
●
Inside (toothed portion) of belt for exposed tensile cords
(normally covered by nylon layer and polyethylene layer).
This condition will result in belt failure and indicates worn
transmission sprocket teeth. Replace belt and transmis-
sion sprocket.
●
Signs of puncture or cracking at the base of the belt
teeth. Replace belt if either condition exists.
●
Replace belt if conditions 2, 3, 6 or 7 (on edge of belt)
exist.
NOTE
Condition 1 may develop into 2 or 3 over time. Condition 1 is
not grounds for replacing the belt, but it should be watched
closely before condition 2 develops which will require belt
replacement.
2002 Buell P3: Maintenance
1.11
Rear Sprocket
Drive Belt
1-19