Zipper's chain conversion problem- Help!

[NO COAST CHOPPER]

I ordered a chain conversion kit from Zipper's. Saved up my money, called Zipper's and they were super helpful. Got the kit in my greedy little hands and when I went to put it on the SHIT DIDN'T FIT!!!!! WTF!

So here's what didn't fit. The front sprocket ( obviously I'm talking about the secondary drive) would not fit the shaft. Now, I was a bit tired and maybe I only gave it a half assed try ( I would try again but its at the shop and can't get to till Monday), but I swear that the sprocket seemed smaller then the shaft. The sprocket is a 22 tooth and its going on a 2004 rubbermounted sporty.

I called Zipper's yesterday and no one would help me expect the guy who sold it to me. I left a message with him and he never got back to me so I called again. He ASSURED me that the product sold to me FIT ALL 5 speed sportsters. He told me he would double check and call me back. He never did.

So my question is this: Does anyone know if the secondary drive shaft is the same size for all 5 speed sportsters? Is there a secret to putting this shit on?

[Mattbastard]

There's two kinds of Rigidmount sprockets, the ones that fit the 86-90 bikes with a fat splines, and the 91-92 ones with the small splines just like the ones on the pulley of your bike. If it's the small splines, it should fit. It takes a delicate touch, but it should go. Take a pic of said sprocket if you want more closure.

[a45junkie]

if they were any tighter it would be a press fit

[crospo]

In 2004 they changed the splines on the shaft.You need one that's specific to 2004 and up.

[NO COAST CHOPPER]

Originally Posted by crospo

In 2004 they changed the splines on the shaft.You need one that's specific to 2004 and up.

Your sure about this? I'm going to the shop monday, I'll take some pics.

[a45junkie]

the splines are the same from 91 to 07 at least
some sprockets require a spacer/seal behind them and some have it built in

[Mattbastard]

All those kits are is basically a set of sprockets for a 91-92 bike, then it also comes with a new spacer that sets the sprocket further out on the shaft, and a new seal because the spacer is a different diameter than the other ones for use with pulleys. And they throw in a high quality chain.

When I discovered this I just took an extra sprocket spacer I had from my 30T pulley purchase, had it machined down to .2", and bought a sprocket on ebay for a 91 Sporty. Much cheaper this way. I think the sprocket was $36, rear sprocket was $40, machined spacer was $10, and regular ol' o-ring chain can be bought wherever you want.

[Oli1200]

Does the "disclaimer" on the Zippers page about the rubbermount models needing larger front and rear sprockets to clear the passenger peg mount matter to your bike? Unless your not running passenger pegs.

http://www.zippersperformance.com/ca...=822&prod=2167