Didn't know this post was still living...

I changed out the pulley and I haven't had any issues since...knock on wood.

 

Moe, my brother Ultra just found out it had about a 1/4 to 1/2" tear on the belt. Where did you get yours replaced. We work in Prince Frederick, MD. And is it safe to drive for now?>

 

Same for me, 2 belts, 2 different bikes, both had around 45k mi and broke while pullinng a 2nd gear wheelie. I still use the sidecar app belt on my '03 but the 1 1/2 belt doesnt fit the newer bikes with wider rear wheels.

Looks like 1 of his belts has delaminated between the gogs and the backing....

 

Can't help but wonder if that now discarded rear pulley had a center that was slightly off making the belt go from extremely tight to loose and back to very tight with every revolution.

 

@db...lol, the Indy I used is now out of business.

 

Which pulley did you replace?

 

What is the best way to see if your belt is to tite? What is proper way to measure tension and what is acceptable.

 

HD sells a tension tool or you can do the twist method. Do you have a service manual.

 

Absolute crap,how is twisting the belt going to give the correct tension??

 

I did replace the rear pulley (w/ a stock) prior to all the belt issues. That pulley was bought from a forum member here, not sure if thats the issue or not, it wasnt brand new but all who have looked at it says it looks fine. Thats probably what I'll do, get a new rear pulley.