Was it a Kawasaki LTD454 that MMRanch used? I've been thinking about doing this. I have access to a lathe and a milling machine so other than the sprocket it's only going to cost me a bit of time.

Thanks, Serowbot. I priced a sprocket when my dealer had my bike pulled up onscreen last summer. About $90. But that was the guy from the back; not the owner, so who knows. Sadly they had trouble getting ATVs and bikes dried up in 2011. They dropped Suzuki and are selling the devil out of Polaris ATVs. Added a little gunshop in the back. Now if they just had recliners....

$5 ?... you lucky dog

I found one for about $20, turned out to be scrap as the teeth were worn.  To his credit he made good on it and refunded the entire cost.  I may try JB weld on the teeth... later.

Did you try to rotate the pulley on the shaft... maybe it's out of round.

Well Guys

Serowbot looks like you did a great job on making it fit and the pictures are Great !

I doin't know what to say ...  I'm running mine ..    At 55 on the speedo I pass everything on the two lane all the way to any of the local towns.

I chucked it up in the lathe to take off the excess thickness in the middle , but !!!  

the thing is made of steel as hard as the tool steel cutter I tried to cut it with.   So it was out with the angle grinder.   While it was spinning in the lathe I took what I thought was  .010 or .015" off the outside dia. kinda "Just to true-it-up  sort of thing.   The first time I started out with it there was a rub against the outer cover so I put a washer (1/4") between the cover and the case to make it stand out an extra .040" or so.  

Been happy with it every since.  

I put a new tire on this year :   140/90-15 comander II .    There is only an extra .5" in the front right corner of the swing arm.   but its plenty.

I"m  still somewhat perplexed about the noise comming out of the Head.  OldFeller might have hit the nail on the head with an idea of Valve timing , I might have it one tooth to fast ???  

Versey   I'll meet ya on the Knock, Knock  thread .   going there now!


Serowbot  
The difference has to be in the depth we took of the middle of the 25 tooth pulley.   And it can only be a matter of less than .050" .   I didn't do near as neat a job as you did , Just kinda eye-balled it in !   If its rubbing the case on the backside , then how about putting the Kawasaki splined washer behind it and taking the same distance off the front as to break even (minus a miro-wabble).

Just guessing ???

My thought is,.. with steel this sturdy,...(and it is just eyeball ground), but if the inner surface angle isn't true, the splined shaft won't allow the pulley to go off kilter...
If it does,... it ain't as tight as the stock one...

All theory, and guessing,... I just didn't feel comfortable risking it...
If the shaft gets buggered,.. the engine is toast.

But... I could have gotten a bad one...

PSS... I originally went to the scrapyard last week, and the guy said $35... came back on the owners day off, and a different guy said he felt guilty charging me $5 for such a gruddy thing...
Shop around,... and re-shop around...  ...

I'm not saying don't try it,... or do.... just relating my experience...
I was originally photo-documenting to make a how to... with MM...
Hope the pics still help anyone else trying it.. even fail pics might be helpful...
Wish I'd had a lathe... I did it clamped in a workmate table walking in circles...
Dizzzzzzy!!!.. ...

PS... grinder boo-boo's really hurt!... much nastier than a straight cut...
Tiny dig, on my left pinky... but my band buddies are going to call me a "pu$$y" this weekend...
... and I am...
(never run a guitar string into a cut, new realms of S&M...)...

Best luck... if results are good,... I may take another shot at it...
Enjoy the experience,... of a bike that isn't a cookie cutter custom...
Every mod on this site, is the result of experiment...
...

Serobot...
Could you take the pulley you have now to someone who could grind it on a lathe now? What you've done so far looks so very close, it shouldn't take much off to get it just right; might be worth another shot at it, especially if it's working for MM...