2000 Harley Davidson FLHTCUI Electra Glide Ultra Classic Logo
Posted on Sep 26, 2009
Answered by a Fixya Expert

Trustworthy Expert Solutions

At Fixya.com, our trusted experts are meticulously vetted and possess extensive experience in their respective fields. Backed by a community of knowledgeable professionals, our platform ensures that the solutions provided are thoroughly researched and validated.

View Our Top Experts

How to replace drive belt on 1996 Harley FLHTC. I have a lift and full set of auto tools. Is it advisable for a home project?

1 Answer

Anonymous

Level 3:

An expert who has achieved level 3 by getting 1000 points

All-Star:

An expert that got 10 achievements.

MVP:

An expert that got 5 achievements.

Brigadier General:

An expert that has over 10,000 points.

  • Master 4,565 Answers
  • Posted on Sep 27, 2009
Anonymous
Master
Level 3:

An expert who has achieved level 3 by getting 1000 points

All-Star:

An expert that got 10 achievements.

MVP:

An expert that got 5 achievements.

Brigadier General:

An expert that has over 10,000 points.

Joined: Sep 22, 2009
Answers
4565
Questions
0
Helped
2156079
Points
14358

The final drive belt can be replaced using regular tools for the most part. You will need a way to "Lock" the primary chain so you can retorque the compensator sprocket nut and the clutch hub nut. The clutch hub nut is left handed threads so you'll need a torque wrench that will torque left handed fasteners.

First, disconnect the battery. To start with, you're going to have to pull the outer and inner primary cases to get to the belt. This means that all of the clutch components are going to have to come out. This can be done at home if you have a good (I mean good) air wrench. The compensator sprocket (engine sprocket, right hand thread) is Loctited at 150-165 foot pounds of torque. The clutch hub nut is torqued to 60-80 foot pounds left handed thread. Make sure your torque wrench will work with left handed threaded fasteners. Take the starter "jack shaft" off. You'll have to remove the starter as well to get the inner primary off. On the FLHTC, I think there is one bolt on the back side of the inner primary with a large braided ground ******** it. This bolt must come out if it's there. Without going outside and getting a book, I think there are four bolts on the engine end of the inner primary, the two starter bolts (3/8" socket head bolts), two bolts or nuts on the inside at the transmission end, and the one bolt down low on the backside of the inner primary. The inner primary should come off easily once you get all the bolts out. You should not have to pry it off. If it doesn't come off easily, double check for bolts that you may have missed.

Once you remove the clutch assembly, you will see the clutch release rod sticking out of the mainshaft. If you pull on this shaft and it comes out, you'll have to pull the right side of the transmission cover to reinstall the clutch release bearing (throwout bearing). It's held on by a very small circlip. If the rod pulls out, the circlip has come off and the throwout bearing has fallen down into the bottom of that chrome cover on the right hand side of the transmission.

Once you get the inner primary off, you will see the front belt pulley. Now, you must remover the rear wheel and the swing arm to get the belt off. You'll need to raise the rear wheel and support the bike with the rear wheel off the ground. You'll need to support the transmission as well since the swingarm acts as the rear motor mount on the transmission. The rubber bushings in the swingarm may have to be repostioned in order to get the swing arm back into position. I use a piece of theaded rod, a couple of nuts and a couple of large washers. I put the threaded rod through the swing arm with the washers and nuts inbetween the bushings. Use the nuts and washer to "press" the bushing towards the outside of the swingarm, spread the bushings so the swingarm will go back into position.

Now, you can work the old belt out. It is much easier if you can get the front belt pulley off but this requires some special tools. A "pulley locking device" and a front pulley locknut wrench. The front pulley locknut is left handed thread and torques to 125 foot pounds with red Loctite. Work the new belt into position and get the swingarm through it. Do not bend the new belt in a radius any smaller than about 4". Doing so will damage the belt and cause premature breakage. Reinstall everything in reverse order.

When you torque the compensator sprocket and the clutch nut, you will have to use a "locking bar" to lock the engine sprocket and clutch outer drum to prevent them from turning while you torque the two nuts. The engine does not have enough resistance to allow you to torque the nuts. Use two lines of Loctite 271 (red) in the compensator nut (right hand thread) and one line in the clutch hub nut, Left handed thread. Torque to specs I gave you in the second paragraph.

Check for proper clutch operation, proper final belt tension, proper rear brake operation before riding the bike. As you can see, this isn't exactly a "beginner's" job. It is fairly complicated but it can be done by someone with above average mechanical skills. I would suggest purchasing a service manual specifically for the bike you're working on.

Add Your Answer

×

Uploading: 0%

my-video-file.mp4

Complete. Click "Add" to insert your video. Add

×

Loading...
Loading...

Related Questions:

1helpful
1answer

2004 Harley-Davidson FLHTC/I Electra Glide Classic. Is there somewhere I can find a free wiring diagram for rear lights. Had a burnt blinker module to replace.

Question edited for a lot more clarity, full 'year make model'.
Question moved to model category.

Harley Davidson has a beautiful wiring manual, but they only show 2 pages!

This is partial diagrams. The HD Forums are great.

https://www.google.com/search?q=2004+electra+glide+classic+rear+lights+wiring+diagram


Service Manuals are a better way if you are keeping the bike.

https://www.google.com/search?q=2004+electra+glide+classic+wiring+diagram+pdf

..
0helpful
1answer
0helpful
1answer

Better intructions than hd service manual?

The only thing better than having an authentic H-D service manual is an authentic H-D mechanic standing beside you. I've used H-D service manuals for years and worked on many bikes that I was not totally familiar with. No mechanic in the world knows it all.

Changing the final drive belt on your dresser is a rather large undertaking. Not only do you have to pull the primary drive, the clutch, the starter, and the inner primary, you also have to remove the rear wheel and the swing arm. But, it can be done by anyone with basic mechanical skills. If you have to remove the front belt pulley, you will need some special tools as well to do the job correctly.
0helpful
1answer

How do you change the timing belt on a 2005 civic

public library...Chilton or Haynes auto repair manuals or collisionrepairadvice.com


you need access above and below the car. a good set of tools and patience.  It's almost a full days work


While your in there, check the water pump and the belt tensioner and you may want to replace the other drive belts.  Good luck.
Not finding what you are looking for?

4,919 views

Ask a Question

Usually answered in minutes!

Top Harley Davidson Experts

Arnie Burke
Arnie Burke

Level 3 Expert

7339 Answers

Sean Wright
Sean Wright

Level 3 Expert

2045 Answers

ZJ Limited
ZJ Limited

Level 3 Expert

17989 Answers

Are you a Harley Davidson Expert? Answer questions, earn points and help others

Answer questions

Manuals & User Guides

Loading...