SuzukiSavage.com - Re: 25T Kawasaki Pulley

Welcome, Guest. Please Login or Register :: View Members

SuzukiSavage.com › General Category › Rubber Side Down! › Re: 25T Kawasaki Pulley

(Moderators: verslagen1, Dave, Serowbot)

‹ Previous topic | Next topic ›

Pages: 1

Re: 25T Kawasaki Pulley (Read 54 times)

Irish Bill YaBB Newbies Offline O'l Skool Street Bobbers Rule Posts: 45 Fenimore, New York Gender:	Re: 25T Kawasaki Pulley 02/16/19 at 17:37:09 Just a quick question... I have acquired a Kawasaki EN454 LTD Front Pulley... What modifications do I need to do to make it fit??? I know I have to machine it and will do this but HOW MUCH do I have to mill down???
Back to top	1996 Suzuki Savage Street Bobber, Arlen Ness Air Filter, El Diablo Ape Hangers, Kuryakyn Flame Mirrors with more parts to come... IP Logged

badwolf

Serious Thumper

Offline

Ridin' my Lil'
Bagger - 153k miles
so far

Posts: 793
Palm Beach County, FL
Gender: male

Re: 25T Kawasaki Pulley
Reply #1 - 02/16/19 at 21:05:04

You need to turn the O.D. down till it's no higher than the belt. That is the easy part.
Now the insides that fit over the shaft need to be turned to match the stock pulley. You will need the stock one off to measure. A electric impact wrench is THE tool to take the nut off. The insides are HARD! Cutting them requires a sharp tool and constantly re-sharpening it.
When putting the 25 tooth on, check for clearance BEFORE you tighten it. A Dermel tool will take off the little bit you need to remove.
The rear axle will have to move forward about 6 or 7 mm, so if you are running a bigger tire check for clearance to the front of the swingarm.
Then tape your phone to a piece of cardboard and then to the handlebar, and fire up a GPS speedo app to check the stock speedo. I did both pulleys and a 150/90 15 rear tire and the stock speedo was 23% off!! I ended-up getting a GPS unit.
Good luck!

IP Logged

Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1431	Re: 25T Kawasaki Pulley Reply #2 - 02/17/19 at 07:49:34 I use indexable carbide inserts for the lathe. Still a PITA. The hardened part is pretty tough. Have to cut both sides. Worth it, though.
Back to top	In theory, theory and reality are the same. In reality, they aren't... IP Logged

Irish Bill YaBB Newbies Offline O'l Skool Street Bobbers Rule Posts: 45 Fenimore, New York Gender:	Re: 25T Kawasaki Pulley Reply #3 - 02/18/19 at 07:20:51 OK Cool thank you for the info... This maybe next weeks project... Will let ya all know how it goes...
Back to top	1996 Suzuki Savage Street Bobber, Arlen Ness Air Filter, El Diablo Ape Hangers, Kuryakyn Flame Mirrors with more parts to come... IP Logged

stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2630 Auburn, AL Gender:	Re: 25T Kawasaki Pulley Reply #4 - 02/18/19 at 09:42:48 Installation overview and images at link below. Does not address the altering of the pulley itself. http://suzukisavage.com/cgi-bin/YaBB.pl?num=1484806731
Back to top	2008 \| 152/52.5–Air Mix 3/4 \| RT6 w/Redline \| Seat Lift w/Sheepskin \| Speedo Rattle \| Rear Pulley Shim \| 140/90-15 Rear \| Kaw Front Pulley \| Relocated Rear Signals FREEDOM ISN'T FREE! IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: 25T Kawasaki Pulley Reply #5 - 02/18/19 at 10:27:19 IIRC Dave included a washer that Is necessary. Could just be a lump in a brain fart.
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

Dave

YaBB Moderator
ModSquad

Offline

SuzukiSavage.com
Rocks!

Posts: 17817
Camp Springs, Kentucky
Gender: male

Re: 25T Kawasaki Pulley
Reply #6 - 02/18/19 at 11:11:21

justin_o_guy2 wrote on 02/18/19 at 10:27:19:

IIRC Dave included a washer that Is necessary.
Could just be a lump in a brain fart.

You can re-use the old lock washer if you are on a budget and don't want to spend $1.67 on a new one (Part# 09167-25019). I also install a low crown head screw for the oil seal retainer....and the bottom of the shift linkage cover, as the belt can rub on the stock bolt and make some nasty sounds.

Someday I will be old......But not today!

IP Logged

stewmills Serious Thumper Offline Imagination is more important than knowledge Posts: 2630 Auburn, AL Gender:	Re: 25T Kawasaki Pulley Reply #7 - 02/18/19 at 11:12:06 justin_o_guy2 wrote on 02/18/19 at 10:27:19: IIRC Dave included a washer that Is necessary. Could just be a lump in a brain fart. Correct. The stock washer you remove can be reused if you don't mess it all up, but Dave did supply a new one just to be safe.
Back to top	2008 \| 152/52.5–Air Mix 3/4 \| RT6 w/Redline \| Seat Lift w/Sheepskin \| Speedo Rattle \| Rear Pulley Shim \| 140/90-15 Rear \| Kaw Front Pulley \| Relocated Rear Signals FREEDOM ISN'T FREE! IP Logged

Pages: 1

‹ Previous topic | Next topic ›

« Home