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General Category >> Rubber Side Down! >> Pulley fondling
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Message started by Armen on 06/24/16 at 13:40:37

Title: Pulley fondling
Post by Armen on 06/24/16 at 13:40:37

Decided to do the Kawi 454 front pulley and step up the gearing a bit. There were some truly nasty ones on Ebay. New one on Bandit with the AMA discount was only $90, so I went for it.
Kawi pulley weighed in at 6+ ounces more than the stock Suzi-Q. Whittled down both sides to match the dimensions (thickness and offset) of the stock. Couldn't control myself, and drilled a bunch of holes as well. Still a few ounces more than stock, but much closer ;)
FWIW, I cut it on the lathe with a carbide insert tool. Pretty easy, although I'd guess the inner surface of the spline was hardened because it sounded and cut nastier in that area.
-Armen

Title: Re: Pulley fondling
Post by Armen on 06/24/16 at 18:13:35

Dummied it all up tonight. Thanks to all the folks who figured out this could work :)
The extra 2 teeth on the pulley make the belt a REAL tight fit. Couldn't jump it over the edge of the pulley, had to mount the belt to the front pulley and slide it on.
I swapped out the two 8mm head bolts to button heads. But besides those, the bolt at the bottom of the pulley drags on the belt. I'm using the 2" longer RYCA shocks. Prob not an issue with the stock shock (swingarm angle).
I'll countersink the hole and use a flat head allen for that spot.
Moving along...

Title: Re: Pulley fondling
Post by Armen on 06/25/16 at 05:22:20

I'll probably slot the leading edge of the axle slot in the swingarm to make it easier to put the belt on.
No biggie, just more stuff...

Title: Re: Pulley fondling
Post by old.indian on 06/25/16 at 06:13:18

I made life easier for myself by having the bike on a lift with the rear wheel jacked up and spinning . At that point I was able to "trim" belt guards etc. as needed . (Spin a little. Trim a little ..... . Spin a little. Trim a little.) It was a bit tight, but I got everything together without having to lengthen the axel slots. The results are worth the effort. :)
old.indian ( 25 tooth Kawa front pulley and 12" Intruder 800 shocks)