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Keep & Kill
Last Post: fafcpa
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27th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2021
Posts: 21 Sportster/Buell Model: XL Sportster/Buell Year: 1995 Other Motorcycle Model: FLHR , 92 FXR Other Motorcycle Year: 97
Reputation: 10

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Rear Sprockets
Bike was running PBI Dished 2072 Aluminum made for 530 chain , then machining Sprockets to except a 520 chain , trying to make options for Sprockets easier so tried using Flat 520 Sprocket with a spacer , But the Sprocket Bolts are about rubbing the swingarm , if i remove washers from bolts there is room , but do i dare not use a bolt washer on a aluminum Sprocket ? options ?
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27th February 2021
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 614 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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Counter bore the sprocket and use a 12 point screw.
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'54 KHK (Current Build), '13 XL”72” Hard Candy, '97 Honda Valkyrie. I’m Retired 🥃
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27th February 2021
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Senior Master Custom Bike Builder
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Join Date: May 2010
Location: Pottstown PA.
Posts: 14,505 Sportster/Buell Model: xlch Sportster/Buell Year: 1960
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Quote:
Originally Posted by hbkeith
but do i dare not use a bolt washer on a aluminum Sprocket ? options ?
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it wouldn't stop me.the hardness is way up there on those aluminum sprockets.has to be similar to steel or they would wear out quickly.if that was your concern.
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72 1000cc barrels and heads, s&s 41/2'' flywheels, sifton cams, s&s super B w/ zippers thunderjet w/yost powertube, andrews gears,and shafts, competition engineering kevlar wet or dry clutch, 72 oil pump, morris magneto w/auto advance and single fire module, cycle electric generator w/electronic regulator,73 cu.in.
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27th February 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2021
Posts: 21 Sportster/Buell Model: XL Sportster/Buell Year: 1995 Other Motorcycle Model: FLHR , 92 FXR Other Motorcycle Year: 97
Reputation: 10

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thinking about cracking at bolt holes without a washer
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2nd March 2021
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XL FORUM TEAM MEMBER
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Join Date: Feb 2008
Posts: 7,466 Sportster/Buell Model: 883 Xl Sportster/Buell Year: 1992
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Quote:
Originally Posted by hbkeith
thinking about cracking at bolt holes without a washer
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I would and have. Look for button head star bolts, flange on the bolt and low profile. Keep an eye on things
fwiw: I run 520 on both street bikes, flat rear sprocket, no spacers. Plenty of room
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2nd March 2021
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XL FORUM TEAM MEMBER
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Join Date: Feb 2008
Posts: 7,466 Sportster/Buell Model: 883 Xl Sportster/Buell Year: 1992
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Flat 530 without spacer was factory in 91/92 on some models
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2nd March 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2021
Posts: 21 Sportster/Buell Model: XL Sportster/Buell Year: 1995 Other Motorcycle Model: FLHR , 92 FXR Other Motorcycle Year: 97
Reputation: 10

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Thanks , my swingarm is strecthed but stock width , running a 4.5" Akront wheel with 160 Stealth , front spocket is spaced out 1/2" , i needed a 1/4" spacer for rear to run flat sprocket
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8th March 2021
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Master Mechanic
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Join Date: Apr 2011
Location: a house
Posts: 269 Sportster/Buell Model: pending Sportster/Buell Year: 2001
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Quote:
Originally Posted by brucstoudt
it wouldn't stop me.the hardness is way up there on those aluminum sprockets.has to be similar to steel or they would wear out quickly.if that was your concern.
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I was thinking about that this weekend. Just swapped from belt on my '01 using PBI parts. I rapped on the rear sprocket (aluminium) with a knuckle, and it rang like a bell. Gotta be a pretty good alloy with a hard heat-treat.
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8th March 2021
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 614 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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Most likely 7075 with a hard anodized surface. The Anodizing process creates an AL2O3 ( Aluminum Oxide) layer that is a actually the same molecule that standard grinding wheels are made of.
You start with an Aluminum alloy that has a heat treated tensile strength that can be better than mild steel and then add a surface treatment that raises its abrasion resistance to that of a heat treated alloy steel with significantly less weight.
Ain’t science grand ?
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8th March 2021
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XL FORUM TEAM MEMBER
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Join Date: Jan 2020
Location: Loxahatchee, FL (S. FL)
Posts: 1,140 Sportster/Buell Model: XLCH Sportster/Buell Year: 2003 Sportster/Buell Model #2: XL Sportster/Buell Year #2: 1981 Other Motorcycle Model: FXDC Other Motorcycle Year: 2013
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You know your metals, Tim
I didn't know alum could be that hard.
__________________
Steve
'81 Andrews "Y" cams, K. Black 9-1 pistons
'03 1250 NRHS stage two Lightning heads, 536, mik 42
'01 Cyclone
'13 FXDC 96" stock
Last edited by Steve9; 8th March 2021 at 14:22..
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