When I went to mount the longer spline pulley I made for myself....I also discovered the need to taper the splines.

I don't know if this is the best method for machining the Kawasaki pulley for the general public. - but it does provide a longer spline for the pulley and I thought that was a good idea.  I took pulley spacers off two engines - and they are really stuck on the shaft and getting them off was very difficult.  There is a rubber O-ring inside the spacer that keeps oil from flowing out between the spacer/shaft - and when it is hard and has congealed oil and rust gluing the spacer on.....it required a lot of yanking and wiggling with big Channel Lock pliers to get it loose. (I don't have any spares).

I like the reduced rpm that the pulley allows - my engine upgrades and lighter Cafe' bike have offset any acceleration drop caused by the pulley.....I am also running a lighter 18" aluminum rim and a 130/70-18 rear tire.  

Ruttly:

The 130/70-18 does not fit a 2.50" rim properly....I have a 3.50" wide rim on my Cafe' bike.  I did the RYCA thing with my first tire and put the 130/70 on a 2.50" rim - and the sidewalls are pulled in too far and the tread profile becomes overly rounded.  I wore out the middle of the tread in 6,000 miles, and the tread on the sides was impossible to reach no matter how far you lean over.  You did good by using a 120-90.

Yes, I am using a 25 tooth front pulley and a 65 tooth rear pulley.  Stock is 68/23 (2.9565) and mine is 65/25 (2.6). In 5th gear my engine is turning 3,500 rpm at 60mph, and 4,000 rpm at 70mph.  The double pulley setup is not for everyone - currently only Badwolf and I have that gearing on our bikes.  The double pulley setup moves the axle way back in the swingarm slots - I have plenty of room for the 130/70-18 tire without modifying the swingarm for clearance.

After that we hit the twisties ! ! !

Ruttly wrote on 02/05/23 at 14:19:59:


My 101.1 was confirmed by my GPS speedometer....but the bike just wouldn't go any faster.  The accuracy of the GPS is confirmed by the Garmin - but they both are likely using the same satellites!

I believe my 38mm carb , stock header and double baffled muffler are likely a bit of a hindrance for my terminal velocity.  My fastest mph is obtained in 4th gear - in 5th the engine stops pulling at around the 85-90 mph range.  The smaller carb and restrictive muffler do however run really smoothly, and the neighbors appreciate that the bike is pretty quiet (they have all their fingers up when they wave at me).

Most of my riding is done at 50-60mph on the back roads and I seldom need more than half throttle to stay at the speeds the roads can allow.  I will be removing the 95mm pop top Wiseco and installing a 97mm flat top before long, installing the MAC header and a muffler that I got from DragBikeMike......and installing a steering damper as the darn bike gets wiggly as you approach triple digits!

A small hose clamp works great on the dowels too.  Just make sure there is a bit of clearance between the worm-screw and the deck so you don't mar the critical sealing surface.

Yeah I’m a bad influence to all I meet ! But that’s the whole point of the gps speedo & rewire. Get data , well I think it only does 0-60 , 1/4 mile , WFO/ top speed. After all that you can bet , I’m gettin some numbers to post. I just want to know if it’s worth a Dyno session. It would really have to impress me before I did that. I don’t think it’s all that fast. We will see.