I am looking for a smaller transmission pulley for a 2004 Roadster. I have replaced the stock 29 tooth transmission pulley with a 28 tooth 883 transmission pulley and the result was barely noticable at best.

I would like to find a 26 tooth (or less) transmission pulley. In 2004, the MoCo (http://www.harley-davidson.com) changed the transmission splines; making this search even more difficult. Not many aftermarket companies are making various sizes of transmission pulleys for the newer Sportsters.

Any help would be greatly appreciated.

JB

I've never heard of a smaller pulley than 27. You may have to play with the rear one to get what you want... whatever that Is. Remember, the shorter your overall gearing, the less your top end will be and the higher rpms at cruising.

Jesse
First off, welcome to the forum. Second, their are many here more technically qulaified than me, but my question is "what is the end result performance you are trying to achieve?" Racing Off the line........low end torque.......more noise from the pipes at lower speed.....more whine in the shift???????

:yikes OMG I didn't even notice he was a newbie... :welcome aboard. Git yerself over to the intro so we can all say hi.

I've never heard of a smaller pulley than 27. You may have to play with the rear one to get what you want... whatever that Is. Remember, the shorter your overall gearing, the less your top end will be and the higher rpms at cruising.

Thanks for the response!

Already I have replaced the stock 68 tooth rear pulley with a 70 tooth rear pulley. Additionally, I have replaced the stock 38 tooth engine sprocket with a 34 tooth engine sprocket along with a shorter primary chain.

Now I'm back on the transmission pulley. As tall as these gears are, SOMEONE is going to make smaller transmission pulleys for the newer Sportsters. I want to get one when they become available.

JB

The 68 to 70 (I thought stock was 63) was a waste of money. Two teeth on the rear won't even be noticed.

Don't hold yer breath. They make 'em according to overall demand. Ya might check with some of the racer types.

Jesse
First off, welcome to the forum. Second, their are many here more technically qulaified than me, but my question is "what is the end result performance you are trying to achieve?" Racing Off the line........low end torque.......more noise from the pipes at lower speed.....more whine in the shift???????

Wheelies!!! Beginning at a lower speed.

Stock, my 2004 Roadster topped out 40 mph in first gear. Methinks that is a tad too fast to be shifting into second gear to begin riding a wheelie.

JB

There was just such a topic in here last week. The guy wanted to do stunt wheelies and asked the same questions. stevo, one of our top resident performance gurus had a lot of advice for him. Look for the post.

The 68 to 70 (I thought stock was 63) was a waste of money. Two teeth on the rear won't even be noticed.

Don't hold yer breath. They make 'em according to overall demand. Ya might check with some of the racer types.

Tell me about it! :( I feel like everything I've done thus far has been a waste of money. The overall ratio is no where as low as I want it to be. I'm not certain what speed first gear tops out at, but I am darn sure it is still too fast to begin riding a wheelie. A SotP guess is 35 mph.

I have a Twin Tech ignition module that will allow me to re-calibrate the speedometer. I'm waiting on a data link cable to complete that task.

I know SOMEONE will make a smaller transmission pulley for the newer Sportsters. That is why I barged into this forum, the shake the trees with my question. I was hoping someone here had pondered this dilemma and had a workable solution.

Maybe we can blaze this trail together. Thanks for everyone's help.

JB

There was just such a topic in here last week. The guy wanted to do stunt wheelies and asked the same questions. stevo, one of our top resident performance gurus had a lot of advice for him. Look for the post.

Believe it or not, I lurked around a bit before I registered and posted my question. I didn't run across the thread you mentioned, prolly because I concentrated my search around the transmission pulley.

JB

Try looking thru the various topic headings

Image test.

http://tinypic.com/19axdh

If these pictures come through, it shows me having fun on my old 1996 Sportster Sport.

http://tinypic.com/19axw2

JB

Try looking thru the various topic headings

I did, prolly not good enough as I narrowed my search to the transmission pulley. Hey, I started out under the correct topic. :) Not bad for a newbie, as you call 'em.

I prolly stick around and lurk a bit. There appears to be some intelligent folk in here. :yikes

JB

heres the thread ya might wanna look into (http://xlforum.net/forums/showthread.php?t=1563)

every so often ol' flathead comes thru.

heres the thread ya might wanna look into (http://xlforum.net/forums/showthread.php?t=1563)

Thanks flathead45. On my 1996 Sportster Sport I replaced the belt drive with an O-ring chain. In the pictures I submitted in this thread, I was still running the belt. The reason I went to a chain was because I was breaking belts. Four times in a short period of time. It all started when I installed a soft compound rear tire.

I REALLY don't want to go with a chain on my 2004 Roadster unless I have to.

JB

If yer into stunt work and run the soft compounds, the chain is the only way to go. Those belt drives while fairly dependable under normal conditions just won't hold up under the kind of riding you seem to prefer.