The S&S solution looks promising. I measured the rear sprocket and it is like 1-1/16". Is there an aftermarket sprocket that will accept the wider belt? There does not look like there is alto of clearance for the 1 1/2" near the frame but I'm not positive. If there is an aftermarket sprocket that can use this belt you will have solved the issues of belt breakage when going to the 30T sprocket. Since my bike is sitting on the jack with a broken belt and no clear solution in sight I'm interested in a permanent fix.
41,500 miles on stock sprocket and belt plus allot of horseplay than changed to the 30T kit and put 3,000 miles and had a shredded Falcon belt and I was riding more conservative than ever.
When you changed to the 30 tooth trans sprocket, did you also change the rear sprocket? If not, that sprocket may have been severely worn at 40k plus miles which could damage a new belt rather quickly. Of course, there is always the possibility of just getting a bad belt, and then there is the possibility of the belt being mishandled somewhere along the line. Belts don't tolerate being forced into a tight bend, for instance, and a nick in the belt can lead to premature failure.
The 1" belts on recent Harley's have not shown a tendency for poor reliability, even with bikes pumping out double the stock power. Before blaming the narrow belt (the original of which lasted over 40k miles and was still fine when you changed it btw), I'd look for something else like a worn or damaged sprocket.
Jerry