So, just to be sure, I should be OK with just converting the front pulley for now? I'm looking for a quick solution to raise my top speed while lowering RPMs. Cruising down the highway at 75 MPH+ is a regular thing for me. (I know I know, the Savage ain't designed for that stuff, but I got it because I need moderation, not a sport bike. I just want to cruise a tad bit more comfortably with the engine pumping like crazy.) I don't have the place or the money to do machine work for the rear pulley. I think I could manage to do the front one on my own in my in-laws garage. I have a 4" grinder to be able to trim part of the gear-box case down where necessary.

I'm only asking, because I know the rear couldn't be done alone.

Also, anyone here know how hard it would be to get a rear pulley machined to the right specs? If I say, drew up some schematics in autocad based on the needed dimensions between the kawa pulley and savage pulley?

Thanks.

savskad wrote on 04/09/15 at 16:35:54:


The pulley itself requires some pretty extensive machining also...

Serowbot wrote on 04/09/15 at 18:12:39:


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What machining does the front pulley need? I read where the rear one needs some work, but the front one, all I saw was hammering the little bits of metal flatter. The rest (for the front pulley) was just trimming the body so the pulley would clear it. Am I missing something?

Ahhh ok....pardon me for missing that part. So the part circled in red is what needs to be trimmed, right? and the corresponding spot on the back side of the pulley? Other than that, no other machining is necessary?

Dave, how much of the front pulley did you have taken off? Are both sides machined flush with the face of the pulley? Do we need to worry about the thickness on the back side so the pulley is spaced correctly or can it be shimmed with washers?

Ok, gotcha.

I may try this instead of chain. The Kawasaki front pulley by itself will yield a ratio of 2.72:1. I was wanting a chain ratio of 2.71:1 but the chain requires a lot more maintenance. Coincidentally the Kawasaki pulley is almost exactly the ratio I was looking for. Thanks!

Dave,   I have been looking on ebay, and found several front pulleys for the kaw vulcan quite cheap.

http://www.ebay.com/itm/252305379440?_trksid=p2060353.m1438.l2649&ssPageName=...

Do you know if they are the same as the ones off the old 450's we're using? They count 25 teeth, and LOOK the same in the pictures, but??? If they work I would get one, turn it to fit, and be able to supply a few guys at a reasonable price who want to gear up. I thought cost plus $50 and shipping.

Dave, I did not know you were working on the same thing/idea. Don't want to step on your toes. When I did mine just chucked it up in the 3 jaw and that worked fine. Seemed to be enough interest here from time to time that someone should offer a couple and see if people are willing to actually pay something or just dreamers/bitchers. I'll let you handle it as you're already invested. Good luck!