Pulleys

Belt Pulleys

All big Harley-Davidson Twins from 1985 onwards and all Sportsters from 1991 onwards have toothed belt pulleys. Well, of course in their original, non-customized state. There is not as wide a selection of pulleys as there is of sprockets, and rear wheel pulleys in particular are only available in wide steps of teeth numbers. Adjusting the transmission ratio is therefore quite difficult.

Are there offset pulleys available?

They are rarer than offset sprockets, but yes, they do exist. However, because the drive belts to the rear wheel are already very wide compared to a chain, many mechanics prefer to convert to a chain.

Does one have to replace belt pulleys? And if so, which are the replacement periods?

Harley-Davidson sets the belt pulleys on the maintenance schedule every 8,000 km (5,000 mls). They are checked for damage and wear at this interval and replaced if necessary. This is required if the surface of the teeth is badly corroded and damaged. Also if the teeth show disruptions or dents. Unfortunately, the belt covers do not keep out all foreign bodies and occasionally, grit or similar is embedded. The Factory also recommends replacing the pulleys at the same time as the belt.