Hey everyone. I need some help/advice on aligning the belt on the pulley for a 2005 Sportster. So, I had the rear wheel off to install a new rear tire. I set the belt tension and alignment by measuring the threaded portion of the adjuster and made sure that they were within a few thousandths of each other. I have ridden 5he bike a couple o& hundred miles since then with no issues. I was looking the bike over this weekend and noticed the when looking from the rear, the belt is all the way against the right edge of the pulley. I have re Che led my original adjustment and it was ok. I even readjusted by measuring from the center of the swing arm bolt to the middle if the rear axle and made sure both were the same. When I rotate the shell, the belt still stays to the right side. I have checked and my spacers are in the correct locations.
Anyone have any suggestions as to how to “fix” this? The bike only has 11k miles and there does not appear to be any damage to the pulley or belt. Also, I do not have a service manual.

thanks,

mike

 

This is normal. You will never get the belt to track down the center of the pulley. If you spin the wheel backwards it will track to the opposite side.

 

Don't set your belt tension by the length of the adjuster sticking out. They may be different lengths, especially if your bike is second hand. Take a metal coat hanger and some tiny o rings and measure the distance from the small hole in the swingarm to the center of the axle and mark it on the coat hanger. Adjust the other side to match
this won't change where the belt rides in the pulley. but it is the easiest and surest way to make sure your wheel is straight
edit, I see you did this and I read to quick.

 

It won't hurt anything as long as the belt doesn't rub on the side of the pulley or damage the edge of the belt.

 

This ... I suggest welding rod over a coat hanger as it is straight and less flexible

 

Get the rod from Home Depot or whatever you go to for building stuff. Here is a link to a youtube video that will show you how to make it so it is almost exactly just like the one HD sells: