Drive belt handling
See Figure 5-36.
- Do not exceed 5 in (127 mm) forward bend (1).
- Do not exceed 10 in (254 mm) reverse bend (2).
- Do not twist (3).
- Do not crimp, pinch or kink (4).
- Do not pry (5).
![](https://motoinstruction.ru/img/harley/12/118167.jpg)
Figure 5-36. Drive belt handling
Drive belt: XL models
FASTENER | TORQUE VALUE | |
Exhaust pipe clamp bracket fastener: XL Models | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Axle, rear, nut | 95-105 ft·lbs | 129-142 Nm |
Removal
1. Remove mufflers and rear exhaust pipe. See 4.13 EXHAUST SYSTEM: XL MODELS.
2. Mid-Mount Controls: Remove right side rider footrest/brake pedal and mounting bracket assembly. See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
3. See Figure 5-37. Remove screw (6), washer (5) and exhaust pipe clamp bracket (4).
![](https://motoinstruction.ru/img/harley/12/118168.jpg)
Figure 5-37. Sprocket cover: XL models: 1. Sprocket cover; 2. Screw; 3. Screw; 4. Exhaust pipe clamp bracket; 5. Washer; 6. Screw
4. Remove two screws (2, 3).
5. See Figure 5-38. Remove E-clip (1). Discard E-clip.
![](https://motoinstruction.ru/img/harley/12/118169.jpg)
Figure 5-38. Drive belt adjustment: XL models: 1. E-clip; 2. Axle adjuster nut (2); 3. Axle adjuster (2); 4. Axle nut; 5. Washer; 6. Protective cap (2)
6. Loosen rear axle nut (4).
7. Turn the axle adjuster nut (2) on each side of rear fork an equal number of turns counterclockwise to decrease belt tension.
8. Remove right lower shock absorber screw, washer and locknut. See 2.24 SHOCK ABSORBERS, Removal.
9. Remove the belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Belt Guard: XL Models.
10. Remove the debris deflector. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Debris Deflector: XL Models.
Warning! Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over bending can damage belt resulting in premature failure, which could cause loss of control and death or serious injury.
11. See Figure 5-39. Remove belt.
![](https://motoinstruction.ru/img/harley/12/118170.jpg)
Figure 5-39. Drive belt removal: XL models
Installation
1. Install belt onto sprockets.
2. Install the front of belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Belt Guard: XL Models.
3. Install the debris deflector. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Debris Deflector: XL Models.
4. Install right lower shock absorber bolt, washer and locknut. See 2.24 SHOCK ABSORBERS, Installation.
Note. See Figure 5-37. Short screw (2) goes in bottom hole. Long screw (3) goes in top hole. Do not tighten screws.
5. Install sprocket cover (1). Secure with two screws.
6. Install exhaust pipe clamp bracket (4), washer (5) and screw (6).
7. Tighten:
- a. Exhaust pipe clamp bracket fastener 30-33 ft·lbs (40.7-44.8 Nm)
- b. Sprocket cover fasteners 80-120 in·lbs (9.0-13.6 Nm)
8. Mid-Mount Controls: Install right side rider footrest/brake pedal and mounting bracket assembly. See 2.40 RIDER FOOT CONTROLS: XL MID-MOUNT CONTROLS.
9. Install rear exhaust pipe and mufflers. See 4.13 EXHAUST SYSTEM: XL MODELS.
10. Adjust belt tension. See 1.12 DRIVE BELT AND SPROCKETS, Drive Belt Deflection.
11. Check wheel alignment. See 1.24 WHEEL ALIGNMENT.
12. See Figure 5-38. Tighten rear axle nut (4) to 95-105 ft·lbs (129-142 Nm).
13. Install new E-clip (1).
Idler pulley: XR 1200X
FASTENER | TORQUE VALUE | |
Idler pulley fastener: XR 1200X | 70-80 ft·lbs | 95-109 Nm |
Idler pulley bracket flanged nut: XR 1200X | 33-35 ft·lbs | 44.7-47.5 Nm |
Sprocket cover, rear screw | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Removal
1. See Figure 5-40. Remove sprocket cover (1).
![](https://motoinstruction.ru/img/harley/12/118171.jpg)
Figure 5-40. Drive belt idler: XR 1200X: 1. Sprocket cover; 2. Bushing (2); 3. Flanged nut (2); 4. Washer (2); 5. Drive sprocket; 6. Idler pulley bracket; 7. Idler pulley; 8. Fastener
Note. It is not necessary to remove the drive belt completely.
2. Release tension from drive belt and slide belt off drive sprocket (5). See 5.6 DRIVE BELT, Drive Belt: XL Models.
Note. If exhaust system interference prevents removal, loosen all exhaust system mount fasteners and flange nuts. Pull exhaust system away from engine to allow room to remove idler assembly.
3. Remove nuts (3) and washers (4). Remove idler pulley and bracket assembly from vehicle.
4. Spin and check idler pulley (7) for bearing wear. See 1.12 DRIVE BELT AND SPROCKETS, Inspection.
Note. The idler pulley bearings can not be replaced separately.
5. If idler pulley needs replacement, remove fastener (8) and bushings (2). Discard idler pulley and replace with new idler pulley (7).
Installation
1. See Figure 5-40. Install new or existing idler pulley (7), if removed. Tighten fastener (8) to 70-80 ft·lbs (95-109 Nm).
2. Install idler pulley and bracket assembly. Install washers (4) and flanged nuts (3). Tighten to 33-35 ft·lbs (44.7-47.5 Nm).
3. Install drive belt and adjust belt tension and wheel alignment. See 1.24 WHEEL ALIGNMENT.
4. Install sprocket cover:
- a. Tighten rear (larger) screw to 30-33 ft·lbs (40.7-44.8 Nm).
- b. Tighten forward and lower (smaller) screws to 80-120 in·lbs (9.0-13.6 Nm).
5. If loosened, align. Tighten exhaust system components. See 4.14 EXHAUST SYSTEM: XR 1200X.
Drive belt: XR 1200X
FASTENER | TORQUE VALUE | |
Sprocket cover, rear screw | 30-33 ft·lbs | 40.7-44.8 Nm |
Sprocket cover, forward and lower screws | 80-120 in·lbs | 9.0-13.6 Nm |
Axle, rear, nut | 95-105 ft·lbs | 129-142 Nm |
Removal
1. Remove exhaust system. See 4.14 EXHAUST SYSTEM: XR 1200X.
2. See Figure 5-41. Remove screws (2, 3, 4). Remove sprocket cover (1).
![](https://motoinstruction.ru/img/harley/12/118172.jpg)
Figure 5-41. Sprocket cover: XR 1200X: 1. Sprocket cover; 2. Rear screw and washer; 3. Front screw; 4. Lower screw
3. See Figure 5-42. Remove E-clip. Discard E-clip (1).
![](https://motoinstruction.ru/img/harley/12/118173.jpg)
Figure 5-42. Drive belt adjustment: XR 1200X: 1. E-clip; 2. Axle adjuster nut (2); 3. Axle adjuster (2); 4. Axle nut; 5. Washer; 6. Protective cap (2)
4. Loosen rear axle nut (4).
5. Turn the axle adjuster nut (2) on each side of rear fork an equal number of turns counterclockwise to release belt tension.
6. Remove right lower shock absorber screw, washer and locknut. See 2.24 SHOCK ABSORBERS, Removal.
7. Remove belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Belt Guard: XR 1200X.
8. Remove debris deflector. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Debris Deflector: XR 1200X.
Warning! Never bend belt forward into a loop smaller than the drive sprocket diameter. Never bend belt into a reverse loop. Over bending can damage belt resulting in premature failure, which could cause loss of control and death or serious injury.
9. See Figure 5-43. Remove belt.
![](https://motoinstruction.ru/img/harley/12/118174.jpg)
Figure 5-43. Drive belt removal: XR 1200X
Installation
1. Install belt onto sprockets.
2. Install belt guard. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Belt Guard: XR 1200X.
3. Install debris deflector. See 2.22 BELT GUARD AND DEBRIS DEFLECTOR, Debris Deflector: XR 1200X.
4. Install right lower shock absorber bolt, washer and locknut. See 2.24 SHOCK ABSORBERS, Installation.
Note. See Figure 5-41. Long screw (3) goes in top hole. Short screw (4) goes in bottom hole.
5. Install sprocket cover (1).
- a. Tighten screw (2) to 30-33 ft·lbs (40.7-44.8 Nm).
- b. Tighten screws (3, 4) to 80-120 in·lbs (9.0-13.6 Nm).
6. Install exhaust system. See 4.14 EXHAUST SYSTEM: XR 1200X, Installation.
7. Adjust belt tension. See 1.12 DRIVE BELT AND SPROCKETS, Drive Belt Deflection.
8. Check rear wheel alignment. See 1.24 WHEEL ALIGNMENT.
9. See Figure 5-42. Tighten rear axle nut (4) to 95-105 ft·lbs (129-142 Nm). Install new E-clip (1).