Page 1 of 2 12 LastLast
Results 1 to 10 of 20

Thread: Fit new belt on old sprockets?

  1. #1
    Junior Member
    Join Date
    Aug 2018
    Posts
    15

    Fit new belt on old sprockets?

    XB12s 2003 - belt snapped after only total of 10,000miles.
    Sprockets have lost some paint on their teeth but if otherwise ok just put a new belt on?
    The local Harley shop have quoted over 1000 dollars for a new sprocket set and say they always replace if the sprockets have over 5000 miles on them. Understandable if new replacement belt isn't compatible with 2003 sprockets, otherwise seems crazy.

    Advice please...
    Thanks

  2. #2
    Senior Member lunaticfringe's Avatar
    Join Date
    Feb 2011
    Location
    AmishLand, PA.
    Posts
    7,519
    Sprockets have lost some paint on their teeth but if otherwise ok just put a new belt on?
    YES

    The local Harley shop say they always replace if the sprockets have over 5000 miles on them.
    ridiculous!



    2003-only belt unique. check each pulley tooth closely for a sharp edge. if 1 or more found then replace.
    ABSOLUTELY replace your 15 year old idler pulley bearings due to age. cheap insurance...simple fun job. link below complete walk-thru. 6203-2RS bearing....quantity 2 needed. available everywhere!
    here ya go.................
    https://www.twinmotorcycles.nl/artik...?cid=7&aid=292
    Last edited by lunaticfringe; 08-27-2018 at 02:10 PM.

  3. #3
    Junior Member
    Join Date
    Aug 2018
    Posts
    15
    If sharp edges found can't just smooth off? If not then just change the damaged sprocket(s) + belt + idler bearings or something else as well in the 21 parts of the whole assembly?
    https://www.twinmotorcycles.nl/websh...5-1633E48477D4

    Thanks!

  4. #4
    Senior Member lunaticfringe's Avatar
    Join Date
    Feb 2011
    Location
    AmishLand, PA.
    Posts
    7,519
    i'll reiterate: your 2003 has unique "one year only" F&R pulleys and belt. those 3 items are quite expensive. inspect the teeth on both pulleys. they're either nice and smooth and serviceable...or they're not. do NOT recommend sanding or filing anything that looks suspect. at the 10,000 mile mark both pulleys should be fine and completely serviceable.
    replace the idler pulley bearings as i stated. other than a good cleaning and correct reassembly nothing else should need replaced. BE ABSOLUTELY CERTAIN to replace the bridge and torque the 4 allen bolts prior to installing the wheel or you'll incur serious damage.

  5. #5
    Junior Member
    Join Date
    Aug 2018
    Posts
    15
    Thanks again. Every tooth on the sprockets seems a bit pitted but not sharp or chipped anywhere, so I've only ordered the 6203 bearings and a OEM belt (Falcon belt from twinmotorcycles about same price but decided to get one from HD).
    What is the "bridge" you are referring to?

  6. #6
    Senior Member lunaticfringe's Avatar
    Join Date
    Feb 2011
    Location
    AmishLand, PA.
    Posts
    7,519
    my pleasure. the swingarm brace or what i refer to as the "bridge" MUST be removed for belt replacement. idiots remove the entire swingarm assembly because they're clueless. circled in pic for you. have the impression you might be SM-challenged. if so i'll post up one more time for you with every single XB torque value. bridge fasteners MUST be torqued properly and in sequence.

    fazer600_2002_1505200318_firebolt1.jpg

  7. #7
    Senior Member lunaticfringe's Avatar
    Join Date
    Feb 2011
    Location
    AmishLand, PA.
    Posts
    7,519
    here as promised. SEE swingarm brace for specs!



    ALL TORQUE VALUE:
    Airbox cover fasteners 12-36 in-lbs 1-4 Nm page 2-88
    Airhorn fastener 72-96 in-lbs 8-10 Nm page 2-74
    Axle pinch fastener, rear 40-45 ft-lbs 54-61 Nm page 2-18
    Axle pinch fasteners, front 20-22 ft-lbs 27-30 Nm page 2-15
    Axle, front 39-41 ft-lbs 53-56 Nm ANTI-SIEZE, Left handed thread, page 2-15
    Axle, rear ANTI-SEIZE
    Follow special instructions, page 2-18
    Bank angle sensor 12-36 in-lbs 1-4 Nm page 2-72
    Brake hand lever housing fasteners 80-90 in-lbs 9-10 Nm page 2-29
    Brake lamp switch fastener, front 7-10 in-lbs 0.8-1.0 Nm page 2-29
    Brake line p-clamp fastener, front 36-60 in-lbs 4-7 Nm page 2-31
    Brake line p-clamp fastener, rear 36-60 in-lbs 4-7 Nm page 2-40
    Brake pedal fastener 22-24 ft-lbs 30-33 Nm LOCTITE 272, page 2-25
    Brake pin hanger set, front 11-14 ft-lbs 15-19 Nm page 2-33
    Brake pin hanger set, rear 11-14 ft-lbs 15-20 Nm page 2-42
    Brake pin plug, rear 22-26 in-lbs 2-3 Nm page 2-42
    Brake reservoir fastener, rear 96-120 in-lbs 11-14 Nm page 2-92
    Caliper banjo bolt, front 16-20 ft-lbs 22-27 Nm metric, page 2-31
    Caliper banjo bolt, rear 16-20 ft-lbs 22-27 Nm page 2-40
    Caliper bleeder valves 36-60 in-lbs 4-7 Nm metric, page 2-26
    Caliper carrier, rear 24-26 ft-lbs 32-35 Nm page 2-19
    Caliper fasteners, front 15-19 ft-lbs 20-26 Nm page 2-33
    Caliper mounting fasteners, front 35-37 ft-lbs 47-50 Nm page 2-33
    Caliper mounting large fastener, rear 18-21 ft-lbs 24-28 Nm page 2-43
    Caliper mounting small fastener, rear 14-18 ft-lbs 19-24 Nm page 2-43
    Chin fairing fasteners 36-48 in-lbs 4-5 Nm page 2-87
    Clutch cable p-clamp 12-36 in-lbs 1-4 Nm page 2-62
    Clutch inspection cover fasteners 84-108 in-lbs 9.5-12.2 Nm Tighten in a crosswise pattern, page 2-70
    Electronic control module fasteners 72-96 in-lbs 8-11 Nm page 2-73
    Engine shroud air scoop 12-36 in-lbs 1-4 Nm page 2-89
    Exhaust header mounting nut 72-96 in-lbs 8-11 Nm page 2-80



    HOME
    Fairing support bracket fastener 16-18 ft-lbs 22-26 Nm page 2-74
    Flasher fastener 30-40 in-lbs 3-5 Nm page 2-72
    Footpeg mount fasteners, rider 108-132 in-lbs 12-15 Nm page 2-81
    Footpeg mount, passenger 25-28 ft-lbs 34-38 Nm LOCTITE 272, page 2-82
    Fork cap 22-30 ft-lbs 30-40 Nm page 2-50
    Fork center bolt 22-30 ft-lbs 30-40 Nm page 2-49
    Fork clamp, lower 13-15 ft-lbs 18-20 Nm LOCTITE 272, page 2-51
    Fork clamp, upper 17-19 ft-lbs 23-26 Nm LOCTITE 272, page 2-54
    Fork damper locknut 22-30 ft-lbs 30-40 Nm page 2-49
    Front fender fasteners 12-36 in-lbs 1-4 Nm page 2-84
    Front isolator bolt 49-51 ft-lbs 66-69 Nm page 2-62
    Front isolator bracket mounting fastener 49-51 ft-lbs 66-69 Nm page 2-62
    Front isolator snubber, upper 12-36 in-lbs 1-4 Nm page 2-62
    Front isolator threaded frame insert 49-51 ft-lbs 66.4-69.1 Nm LOCTITE 222, page 2-62
    Fuse block and relay fasteners 72-96 in-lbs 8-11 Nm page 2-74
    Hand lever pivot fastener 60-120 in-lbs 9-14 Nm page 2-28
    Handlebar clipon fastener, left 24-26 ft-lbs 33-35 Nm LOCTITE 272, page 2-76
    Handlebar clipon fastener, right 24-26 ft-lbs 33-35 Nm LOCTITE 272, page 2-76
    Headlight fasteners 20-25 in-lbs 2.3-2.8 Nm page 2-72
    Headlight support bracket pivot fasteners 72-96 in-lbs 8-11 Nm page 2-73
    Heel guard fasteners, passenger 48-72 in-lbs 5-8 Nm page 2-82
    Heel guard fasteners, rider 72-96 in-lbs 8-11 Nm page 2-81
    License plate fasteners 36-48 in-lbs 4-5 Nm page 2-93
    Main battery ground fastener 72-96 in-lbs 8-11 Nm page 2-92
    Master cylinder banjo bolt, front 16-20 ft-lbs 22-27 Nm page 2-31
    Master cylinder banjo bolt, rear 16-20 ft-lbs 22-27 Nm page 2-40
    Master cylinder cover fasteners, front 9-13 in-lbs 1.0-1.5 Nm page 2-29
    Master cylinder mounting fasteners, rear 72-96 in-lbs 8-11 Nm page 2-38
    Mirror fasteners 72-96 in-lbs 8-11 Nm page 2-94
    Muffler mounting block fastener, rear
    32-36 ft-lbs 43-49 Nm page 2-80
    Muffler strap fastener, front 108-120 in-lbs 12-14 Nm page 2-80
    Muffler strap fastener, rear 48-60 in-lbs 5-7 Nm page 2-80





    Negative battery cable at battery terminal 72-96 in-lbs 8-11 Nm page 2-70
    Oil cooler air scoop 120-144 in-lbs 14-16 Nm page 2-89
    Oil drain plug 29-31 ft-lbs 39-42 Nm page 2-60
    Oil line fittings 29-31 ft-lbs 39-42 Nm page 2-60
    Passenger footpeg mounts 25-28 ft-lbs 34-37 Nm page 2-61
    Passenger seat latch 60-96 in-lbs 7-11 Nm page 2-93
    Pivot shaft pinch bolt 17-19 ft-lbs 23-26 Nm page 2-61
    Ram air scoop 12-36 in-lbs 1-4 Nm page 2-89
    Rear fender fastener 12-15 in-lbs 1-1.7 Nm page 2-84
    Rear remote master cylinder reservoir fastener 48-72 in-lbs 11-14 Nm page 2-38
    Rotor mounting fasteners, front 25-27 ft-lbs 34-37 Nm metric, Replace with new, page 2-14
    Rotor mounting fasteners, rear 25-27 ft-lbs 34-37 Nm metric, Replace with new, page 2-18
    Seat fasteners 12-36 in-lbs 1-4 Nm page 2-95
    Shift lever pinch screw 48-60 in-lbs 5.4-6.8 Nm LOCJTITE 272 (red), Page 2-69
    Shift pedal flange head bolt 22-24 ft-lbs 30-32.5 Nm page 2-69
    Shock mounting fastener, lower 15-17 ft-lbs 20.3-23 Nm page 2-65
    Shock mounting fastener, upper 49-51 ft-lbs 66-69 Nm page 2-65
    Shock reservoir clamp, rear 120-144 in-lbs 14-16 Nm page 2-92
    Sidestand bracket fasteners 25-27 ft-lbs 34-37 Nm page 2-98
    Sidestand pivot bolt 18-20 ft-lbs 24-27 Nm page 2-98
    Sprocket cover fastener 12-36 in-lbs 1-4 Nm page 2-83
    Sprocket fasteners 35-37 ft-lbs 48-50 Nm Replace with new, page 2-18
    Steering stem cap 38-42 ft-lbs 52-57 Nm page 2-54
    Steering stem pinch fastener 17-19 ft-lbs 23-26 Nm LOCTITE 272, page 2-54
    Swingarm brace mounting fasteners 25-27 ft-lbs 34-37 Nm page 2-61
    Swingarm pivot shaft 24-26 ft-lbs 32-35 Nm page 2-61
    Switch housing fasteners, right 25-33 in-lbs 3-4 Nm page 2-66
    Tail body work, lower 36-48 in-lbs 4-5 Nm page 2-93
    Tail body work, upper 12-36 in-lbs 1-4 Nm page 2-93
    Tail frame to frame 21-23 ft-lbs 28-31 Nm LOCTITE 272, page 2-92
    Torca clamp 28-30 ft-lbs 38-40.6 Nm page 2-80
    Valve stem nut 40-44 in-lbs 4.5-4.9 Nm page 2-22
    Wear peg, rider 36-48in-lbs 4.1-5.4m page 2-81

  8. #8
    Junior Member
    Join Date
    Aug 2018
    Posts
    15
    Very useful. Thanks

  9. #9
    Senior Member konarider94's Avatar
    Join Date
    Sep 2009
    Posts
    4,398
    If you dont have the 04+ belt setup already Id take this opportunity to swap. The 03 models had a 72 tooth rear sprocket and 30 tooth front. The 04+ came with 65/27 pulleys. That's the easiest way to confirm what you have, many of the 03 models were upgraded which would be helpful to know before ordering a new belt.

    I do agree that you dont need to swap pulleys because of wear but there is a reason the belt was changed after the first year.

  10. #10
    Junior Member
    Join Date
    Aug 2018
    Posts
    15
    I have a 65 tooth rear sprocket (although the bike was imported & registered in the UK in 2003). Anyone know the part number for the appropriate belt? Thanks.



Page 1 of 2 12 LastLast

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •