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Author Topic: 30t Pulley with a stock belt. It can be done!  (Read 75386 times)

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Fullsac Performance

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30t Pulley with a stock belt. It can be done!
« on: October 07, 2011, 07:46:02 PM »

This aftermarket belt breakage issue has really been bugging me for some time. After returning home from a 3K Montana trip, I sold my 09 107" to a good friend.
He made it about two blocks and the Falcon belt snapped. Did I get lucky to make it home or what? Needless to say the bike was brought back to my shop with a simple WTF
are you going to do about this? I had already been thinking about the possibilty of a tentioner pulley and started heading in that direction. Then I got this idea about the possibilty of lengthening the swingarm a 1/2 inch instead. I decided to check the actual amount behond the stock rear adjustment that the axel needed to go and was surprised to find it was less than 1/4". As a fabricator, what came next was easier than I ever imagined.

This thread is intended to show a simple way for a fabricator to modify your swingarm and run the 30T with the stock OEM belt. I have no plans of offering this swingarm mod. Sorry.

Steve George
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Pic 1,
A simple gusset was welded to the rear of the swingarm to allow .200 of material to be removed with out weekening the axle slot.
« Last Edit: October 11, 2011, 09:21:23 AM by Fullsac Perf »
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #1 on: October 07, 2011, 07:46:39 PM »

Pic 2

The bald guy can still weld.
« Last Edit: October 07, 2011, 07:54:48 PM by Fullsac Perf »
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Fullsac Performance

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Re: 30t Pulley with a stock belt. It can be done!
« Reply #2 on: October 07, 2011, 07:47:09 PM »

Pic 3

Gussets welded and time for grinding.
« Last Edit: October 07, 2011, 07:51:13 PM by Fullsac Perf »
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #3 on: October 07, 2011, 07:47:36 PM »

Pic 4

The axle slot has been lengthened rearward about .200 by hand with a die grinder and a carbide bit. The same tool I use to remove the CVO cores. I bought a brand new 28.00 cross cut carbide bit just for this job. A 1/4 spacer has been added to the cam adjuster face to use the additional space rearward now available. Sorry, no one was around to take a pic of me grinding this out. It took about a half hour for both.
« Last Edit: October 11, 2011, 09:26:04 AM by Fullsac Perf »
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #4 on: October 07, 2011, 07:49:38 PM »

All finished and read to ride! You can definitely see how much closer the axle is to the shock mount. Actually had to clearance the
shock bolt boss just slightly to clear the cam adjuster.
« Last Edit: October 11, 2011, 09:29:45 AM by Fullsac Perf »
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #5 on: October 07, 2011, 08:29:34 PM »


Being a big fan of simple solutions I like that a lot Steve.  Nicely done.  No great stress on the rear of the swing arm anyway and nothing is done to weaken the sides under compression when the axle is tightened.  Gotta love the KISS principle when it works out :2vrolijk_21: .
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #6 on: October 10, 2011, 09:17:04 PM »

so a 30 tooth conversion can be done in the well equipped home shop - for less than a hundred bux?

wow!

im still going to wait till i need to take the primary off for some other reason

<grin>

rode every day the last two weeks to work - in october in minnesota - and the first day i wore ANY jacket home was today in the sprinkles... <grin>

to
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timtoolman

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Re: 30t Pulley with a stock belt. It can be done!
« Reply #7 on: October 10, 2011, 11:47:00 PM »

 Great  idea Steve!!!!
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #8 on: October 11, 2011, 09:17:51 AM »

Great  idea Steve!!!!
Thanks.
Now you have one more thing to do this winter. :2vrolijk_21:

Steve
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fatboi1959

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Re: 30t Pulley with a stock belt. It can be done!
« Reply #9 on: October 11, 2011, 11:10:10 AM »

Steve, The 1 tooth shorter belt HD/PN-40056-07 i am running now. Should i be worried about breakage with this belt? It's hooked up to a 120r. 07 FLHTCUSE2 30/66
« Last Edit: October 11, 2011, 11:23:39 AM by fatboi1959 »
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #10 on: October 11, 2011, 01:44:16 PM »

Steve, The 1 tooth shorter belt HD/PN-40056-07 i am running now. Should i be worried about breakage with this belt? It's hooked up to a 120r. 07 FLHTCUSE2 30/66
That's a 136T OEM belt on an 07. No issues there, let er rip.

Steve
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timtoolman

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Re: 30t Pulley with a stock belt. It can be done!
« Reply #11 on: October 12, 2011, 10:47:52 PM »

yes i do, I actually thought of just weld building up the area's  below and behind the slot, Then machining it back further,  A little ER70S-2  watch the inrterpass temp at 350 degrees and done!  I just put on a chrome inner primary so ill wait till snow flies :huepfenjump3:
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #12 on: October 13, 2011, 07:51:40 PM »

ok.. so the issue is the aftermarket belt? & aftermarket sprocket?

if i use the hd japan belt and the hd trike sprocket its ok?

? to
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #13 on: October 14, 2011, 11:09:07 AM »

after market belt issues
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Re: 30t Pulley with a stock belt. It can be done!
« Reply #14 on: October 14, 2011, 12:04:43 PM »

There have been very few HD belt breakage issues, but the after market has become suspect.

30T sprocket is of no issue, and HD now makes a less expensive choice.
« Last Edit: October 14, 2011, 05:24:31 PM by Keats »
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