Drive belt help

[rokdog13]

2010 XB12Ss
Purchased bike, rode it home 150 miles.
Went for a ride the next day and the drive belt broke.
Trying to install replacement belt that was supplied by the previous owner and I cannot get the pulley back on.
The belt has an inch of play or so WITHOUT the pulley on, and its hard to remove.
I've checked front and rear sprocket counts
Checked belt serial number 'G0500. 1AKF 'which appears to be correct and 135 tooth count.
After installing the belt and failing to get the pulley on I removed the belt which was pretty hard.
Double checked tooth count and serial numbers.
Loosened rear axle up as far as it could go then re-installed it.
I noticed if the teeth on are in the grooves on the top of the rear sprocket it wants to ride up out of the grooves on the bottom.
It's like this belt has shrunk ALLOT or something.
Please help!

[lowkey]

No idea why you have the pulley removed or even which one you are referring to but putting on the belt is as simple as this:

loosen rear axle completely (the threads) but keep it in both ends of the swing arm, the wheel will be cocked to the left.
Have all pulleys on the bike... rear wheel, tension pulley, and front pulley.
Have the belt over the front and tension pulley then you can line up the teeth on the rear and slip it on because the wheel is cocked to the left
thread the axle in that was holding the wheel but wasn't threaded until now, the wheel will now align and belt tension will be set.
Tighten up the pinch bolt and you are done.

[rokdog13]

The pulley I am referring to is the ONLY one on the bike..
the one located just behind and below the front sprocket.
I backed the axle completely out, then threaded it back in 4 turns.
with the pulley removed I put the belt on, which barely fit.
It leaves no play for pulley installation.
Watched the ONE video on Youtube covering belt installation.
The play in that belt is quite a bit.
On my bike before pulley install there is less than an inch of play in the belt and I need several to re nstall the pulley.
Also, The replacement belt I received with the bike purchase barely even fits the rear sprocket.
with the teeth sitting in the grooves at the top of the sprocket they are riding up and out on the bottom
like this belt has shrunk so much the teeth on the belt and sprocket don't even line up.
I've researched the belt, it's the correct one as far as I can see.
My Bike 2010 Buell XB12Ss
replacement belt G0500 1AKF 135 tooth belt.
I checked front and rear sprocket counts, all correct to original specs.

[BuellyBagger]

I don't take the tensioner pulley off when I change belts... shouldn't need to. Not sure how or why the belt cogs wouldn't align with the pulley teeth? Pics?

[lowkey]

rokdog13, so you can't follow step by step or you don't understand the steps... I'm not sure? Nothing needs to be removed to put a belt on, only undo the threads of the axle slip belt over the rear then tighten... can't make it any more clear. You are probably seeing the belt being to stiff (uninstalled) to conform teeth fitment is all.

[Born2Ride]

May in fact have the wrong belt. The belt should have plenty of slack with the tensioner removed,even tho you dont remove it to swap belts.

[lowkey]

You have the correct belt and the latest PN for it available G0500.1AKF

These are the old belt PN's that also work on the SS/STT/ULY

Product has been replaced:
- G0500.1AKE
- G0500.1AKD
- G0500.1AKB

[rokdog13]

I called and talked to an actual Harley tech who's worked on several Buell's and got a concise common sense description of the belt installation procedure.
I got the belt installed in about 20 minutes.
Lowkey, I'm not sure what bike you own or how it may differ.
But the procedure I got from the certified Harley Tech wasn't anything like your description which did not take into account the huge amount of resistance on the belt I installed.
Your description exactly like that youtube video of an older Buell where the guy just slipped the belt on like it was no big deal.
The Harley Tech told me that video was completely wrong and his description of the procedure proved out in execution.
I thought the comment "so you can't follow step by step or you don't understand the steps... I'm not sure?"
was pretty funny considering how wrong it was...

[lowkey]

Interesting... so what exactly were you doing wrong?

[lowkey]

I stand corrected. As per the manual:

DRIVE BELT INSTALLATION
NOTES
• When removing or installing belt, do not bend or twist belt.
Partially slide belt onto sprocket and rotate wheel or belt
damage will occur.
• Never tighten rear axle with swingarm brace removed.
1. Slide belt onto sprocket.
2. Install swingarm brace and tighten fasteners to 25-27 ftlbs
(34-37 Nm). See 2.21 SWINGARM AND BRACE.
NOTE
See Figure 6-42. Occasionally the drive belt is not fully seated
in rear sprocket making it difficult to install the idler pulley. It
will be necessary to follow the outlined procedure in order to
easily install idler pulley.
3. See Figure 6-42. Grasp top and bottom of drive belt and
squeeze together until belt teeth are fully seated in rear
sprocket.
4. While keeping tension on lower belt, install idler pulley
assembly tightening washers and nuts to 33-35 ft-lbs (45-
47 Nm).
5. See Figure 6-43. Tighten rear axle (1) to 23-27 ft-lbs (31.2-
36.6 Nm), back off two full turns and then retighten to 48-
52 ft-lbs (65.1-70.5 Nm).
6. Tighten rear axle pinch fastener (2) to 40-45 ft-lbs (54-61
Nm).
7. See Figure 6-41. Install front sprocket cover. See
2.38 SPROCKET COVER.
8. Install chin fairing. See 2.53 CHIN FAIRING.
9. Install right side rider footpeg mount. See 2.36 FOOTPEG,
HEEL GUARD AND MOUNT: FIREBOLT/LIGHTNING or
2.37 HEEL GUARD AND FOOTPEG MOUNTS:
ULYSSES.
10. Install lower belt guard. See 2.39 BELT GUARDS.
11. Install rear fender (XB12Ss,XB12STT and XB12X models
only). See 2.15 FENDERS.
12. Remove scissor jack from motorcycle.

As stated by myself and others, never had to remove the pulley for ANY reason when it comes to installing or removing the belt, You're welcome anyway for the help even though you didn't use that method...

I'll give you a +1 for not snapping the axle and another +1 for realizing there is a pinch bolt in the swing arm without having to ask... but really it's so dead simple, I've never had a look at installing the belt as the manual lays out.

There is a lot of stuff that can be done faster/less steps than laid out in the manual and if I was charging you by the hour for work, you'd be glad I did it that way. End result is the same you have your belt on now with your procedure (however long it took)... and my belt is just fine with my way (under 2 min on or off the back wheel).

You should also torque your drain plugs as per the manual while you aren't taking forum advice but asking for it. (don't do that... just having some fun!)