Ditching the 34 tooth trans pulley

Energy One
Bhawkins854

Bhawkins854

Member
Im in the process of ordering parts to change out my shredded rear pulley. After all is said and done i would like to gain some power out of all the money I'm blowing on replacement parts. Baker told me if I wanted to change the 34 tooth pulley i would have to machiene the new one down to match the current 34 that is in most big dogs. All new pullies are wider than the current 34 tooth pulley but I'm not sure how much. Has anyone successfully done this?? My buddy owns a machine shop and can do the work for me, but I'm unsure where I would find out what size belt I would need if i went from a 34 to a 30 tooth front pulley? Anyone know if there is some kid of calculation for this?
 
Bhawkins854

Bhawkins854

Member
Going from the stock 34t transmission pulley down to a 32 or 31 would mean reducing the drive belt size from 133 to 132 t. I have ordered my 31 tooth pulley and I'm having my buddy do the machiene work. I will post pictures of the install if anyone else is interested in reducing the tooth count of their trans pulley.
 
ksmike

ksmike

Active Member
I just got done putting on a 32 tooth front pulley on my 2010 Bulldog. It took a little machine work to get it to clear the front pulley cover and clutch actuator ramp assembly. For a competent machinist it is a very easy job. If you have a 65 tooth rear pulley you will have to move the rear wheel back approx. .2" for every tooth smaller on the front pulley. So you can still use the stock belt if you have some rearward adjustment left. You can use a stock early early 1994 and up 2" wide harley pulley. I had about $125 in the whole project including the machine work. It took a couple of test fits to get the required clearance. Because of the clearances at the clutch actuator ramp assemble, I dont think you could go to a 31 or 30 tooth. The 32 tooth works great, and the 31 would be even better if it could be done, but on mine it would take a belt change to go any smaller. It only changed the mph at 75 about 5 mph but it feels much better driving it at all speeds. It should have had a 32 on it from the factory....
 
Bhawkins854

Bhawkins854

Member
I agree it should have come with a 32, baker sells their 6 speed transmissions with 32t pulleys on them.. I can only assume big dog wanted a smooth running pulley so the vibrations aren't as noticeable. Just my opinion. I already ordered a gates 132 tooth drive belt so I'm assuming there will be no problem fitting a 31t pulley. I ordered a baker steel trans pulley, just going to machiene off the 3/8 inches including the flange to match the original pulley. Also ordered a new quad seal, spacer, and mainshaft seal to change out when my pulley is removed. This 34 t pulley that baker made for them is the only pulley I've see that has no flange... Did you remove the flange from the harley pulley or was there enough clearance to leave it o?
 
ksmike

ksmike

Active Member
Here is some pics of my 32 tooth pulley setup.








Yes the outer flange has to be machined off. There is no machine work that has to be done on the transmission side of the pulley. You also have to use a harley "star type" locking plate on the pulley nut. The pictures above is not the finished product, just the first test fit after machining. I marked the pulley with a black marker and turned the wheel over to get an idea where the interference would be. Then I took it back to the machinist and had him whittle some more on it. :up: I did take just a little metal off of the cover plate for the clutch actuator assembly with a die grinder, just for an extra hair of clearance. It works great!

 
Bhawkins854

Bhawkins854

Member
I guess the guy at baker sent me a 32 tooth pulley.. Its probably better that way since this bike already vibrates plenty and it's only gunna get worse.. I took my rear tire off already to get it replaced, do I need the belt and tire on to remove the trans pulley?? I'm going to try to use an impact to remove it with the transmission in first gear, seems like a lot of torque to be sending to the transmission..
 
DynoDave

DynoDave

Guru
Bhawkins854 said:
I guess the guy at baker sent me a 32 tooth pulley.. Its probably better that way since this bike already vibrates plenty and it's only gunna get worse.. I took my rear tire off already to get it replaced, do I need the belt and tire on to remove the trans pulley?? I'm going to try to use an impact to remove it with the transmission in first gear, seems like a lot of torque to be sending to the transmission..
Click to expand...


You could use a trans sprocket locking tool (George's Garage).
 
ksmike

ksmike

Active Member
The nut on my pulley didn't come off that hard. If I remember right I put it in neutral and let the belt take some of the pounding from the impact. The locking tool would have been nice to have also. I think the mass of the pulley takes up most of the impact.
 
Little-Boo

Little-Boo

Well-Known Member
Troop Supporter
Bhawkins854 said:
I guess the guy at baker sent me a 32 tooth pulley.. Its probably better that way since this bike already vibrates plenty and it's only gunna get worse.. I took my rear tire off already to get it replaced, do I need the belt and tire on to remove the trans pulley?? I'm going to try to use an impact to remove it with the transmission in first gear, seems like a lot of torque to be sending to the transmission..
Click to expand...
Keep in mind the nut has to turned to the right (clock wise) to loosen and left to tighten. It is the opposite of righty tighty and lefty loosey. It only has about 65 lbs of torque if I remember correct. :2thumbs:

Carlos :whoop:
 
B

bigdogtech01

Well-Known Member
Little-Boo said:
Keep in mind the nut has to turned to the right (clock wise) to loosen and left to tighten. It is the opposite of righty tighty and lefty loosey. It only has about 65 lbs of torque if I remember correct. :2thumbs:

Carlos :whoop:
Click to expand...
80 ft lbs with lots of RED loctite :2thumbs:
 
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