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S1owner
Posted on Tuesday, July 11, 2017 - 11:26 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes but thats a design for a later date. I want to get it moving so I can run it through its paces.
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S1owner
Posted on Thursday, July 20, 2017 - 02:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok so I am at the end of my patience and really struggling to solve this belt tension issue.
139t belt is too loose a 137 wont even go on and they dont make a 138.
Installed a 29 t front and the 139 will go on without the tensioner but it is wicked tight.
So I am down to 4 options all of which have their own issues
1- buy a 28T bdl pulley , issue it may or may not solve the issue at $120
2- keep the 27 t front and get a 1/4" bigger idler wheel.
, issue is getting that idler has not been successful as of yet.
3- redesign the tensioner either up 1/4" or adjustable.
Issue time and money
4- go to chain drive
Issue money, noise, no adjustability, finding a race conversion swingarm without selling my first born!!!!

Any ideas/thoughts
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Upthemaiden
Posted on Thursday, July 20, 2017 - 07:59 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

One thing worth noting, that I always thought was odd.... everyone with tubers always says to run the belt "scary tight" or you'll wreck your bearings, but the belts that come on an XB are insanely tight, and I don't remember really hearing a ton of issues with them causing bearing problems. I'm not sure if the difference is that the tension comes from the pulley, and when the swingarm moves it takes some of that pressure off the belt at the pulley to even out with the pressure from the axle moving slightly futher away, or if they did something to the XBs that just made those bearing less prone to going bad.

Personally, I'd try slotting one of the mounting holes on your pulley(if that's an option, I don't remember exactly how yours is designed and mounted) so you can just adjust the tension slightly. I've seen plenty of people do that on buellxb.com and don't remember there being any issues with the tensioner not staying put.

Just as a test, is there anything you can think of the temporarily cover the outer edge of your tensioner, like a dense strip of rubber, to increase it's diameter to see if that helps solve your issue before you'd potentially pay to have another one made? Is the outside diameter of your tensioner pulley a common size? Maybe you could find some kind of aluminum sleeve with a matching inside diameter that's 1/4 thick, toss the pulley in the freezer, heat up the sleeve, and slide them together.

Out of your choices, I'd try then in this order:

3

1 or 2- order depending on which is cheaper

4- just as a temporary to get the bike on the road
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S1owner
Posted on Thursday, July 20, 2017 - 03:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have been working on sleeving the pulley to make it bigger. I work nights and would usssually have a machinist on duty but he transfered so I have been looking for a wear ring or something that I can do just that.
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S1owner
Posted on Thursday, July 20, 2017 - 03:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Oh and here is how the Xb belt tension works and how I am trying to set my system up.
As the seingarm pivots up under load it adds distance/ tension to the belt.
The idler is placed close to that pivot point.
So as the swingarm rises it is putting less pressure on the idler wheel but the distance increasing makes up for that missing tension.
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Hughlysses
Posted on Friday, July 21, 2017 - 06:44 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

everyone with tubers always says to run the belt "scary tight" or you'll wreck your bearings,

You meant to say "scary loose".
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S1owner
Posted on Friday, July 21, 2017 - 07:09 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yea I knew what he meant lol
Well I am going this route
Ordered the bdl 28 t aluminum pulley and I am going to slot my pulley mount and either install a set screw in the bottom to keep it locked in or make a shim insert for under it.
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Purpony
Posted on Friday, July 21, 2017 - 01:30 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

i believe they make a 138 tooth x 1" wide for new sportster dont they? not sure on the pitch and all. would that be worth a shot exploring?
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S1owner
Posted on Friday, July 21, 2017 - 02:53 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I think they do but not sure on running a 1" belt
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S1owner
Posted on Sunday, July 23, 2017 - 09:53 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I was able to make my pulley mount hole into a slot so I can move the pulley up. That slong with the new bdl 28 should take care of my issue. Gotta love having a mini mill!!










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S1owner
Posted on Sunday, July 23, 2017 - 09:59 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Also seen this nice machine on facebook. Somewhat made me mad but he did such a nice job. He however swapped the entire power train into the tuber frame. Thats how he got around the tension issue lol!!!
I believe this is one if Dutches friends?








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S1owner
Posted on Sunday, July 23, 2017 - 09:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Alright so down to the fine list
New clutch cable would not work so I shortened the old and it worked perfect.
New brake hose installed
Speed sensor bracket done
All that remains
Hook up front brake switch
Connect wires for speed sensor
Mount front turn signals
Install front pulley and adjust tension pulley should be here by Wednesday
A good cleaning and once over on bolts and we are riding















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Upthemaiden
Posted on Monday, July 24, 2017 - 08:00 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Hope the new pulley works! I think with that set screw, you should be in business. I bet a mini mill would be super useful. Need a mini lathe first, then I'll work on the mill. Is it the rebranded Seig you can get at harbor freight, or something more elaborate?

That list is getting short. It's gonna be weird seeing this bike done. It's been a project as long as I've been on badweb.

I saw that red one on facebook. Good looking bike. I was curious how he worked the FI under that tank, but I see from the second picture you posted that he just put a carb on it.
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S1owner
Posted on Monday, July 24, 2017 - 09:06 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have the harbor freight one. It has its issues but I got it used and it has paid for itself. I also have a little craftsman 109 lathe.
And this project has went on to long
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S1owner
Posted on Thursday, July 27, 2017 - 01:39 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

New bdl aluminum pulley arrived very nice and wow thats alot of rotating mass weight savings
Old 27 - 2 lbs 13 oz
New 28 - 1 lbs 1 oz




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S1owner
Posted on Friday, July 28, 2017 - 12:26 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ok
I am so close
Waiting on a dash piece from Purpony which should arrive soon.
Installed the 28 T pulley and it fit took up some slack but not enough without the idler wheel on. However the Idler wheel now is to big even at its lowest setting. But this is ok because high rpm idlers are widely available and it just so happens Kodiak duramax use a milled steel idler of the correct size!!!!
Ordered and on its way!!!!
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Upthemaiden
Posted on Friday, July 28, 2017 - 08:04 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Did you try the 27t pulley after you made your idler adjustable with the slotted hole? I know you're past that at this point since you ordered the new idler. That 28t pulley looks really nice too. I have random thoughts of going up 1 or 2 teeth in the front someday. I've always done the opposite with my bikes, but with only 5 gears on this thing, I feel like anything over 60mph on this bike just gets too buzzy. I remember my xb9s was the same way, comfortable up to 65mph, but not any higher.
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S1owner
Posted on Friday, July 28, 2017 - 09:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

27 would have still been to loose
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Joesbuell
Posted on Saturday, August 05, 2017 - 07:09 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

My setup works perfect with 26/55 combo and no idler

(Message edited by joesbuell on August 05, 2017)
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Joesbuell
Posted on Saturday, August 05, 2017 - 07:22 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I always ran my tuber belts loser then recommended as i read about it on here somewhere years ago. the idea is if a rock gets in between belt and teeth it won't punch or tear the belt. I even modified my Ulysses tensioner so it ran the belt looser by elongating the mount holes. As I have told you before a 135 tooth belt off an SS/XBT and 26T front and 55T rear works perfect with enough slack even after stretching.I even tested it with the shock removed and swing arm fully raised and lowered. When you got the rear pulley made you should have got a 55T. You'd be enjoying it by now...just saying ; )

(Message edited by joesbuell on August 05, 2017)
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S1owner
Posted on Saturday, August 05, 2017 - 07:57 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Joe
You are 100 percent correct. But I tried to go at it a diffrent way and I do like a challenge.
Who knows I may end up right back at that point.
Its a good thing I really enjoy working through issues!
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Joesbuell
Posted on Sunday, August 06, 2017 - 04:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I worked through all these issues on paper before I ordered or made parts so that it work perfect first time and was easy to use stock parts. The good old keep it simple adage.
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S1owner
Posted on Tuesday, August 08, 2017 - 05:12 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Joe
Had not responded because really had nothin to say. You did a great job and pioneered this swap. I am glad it worked out like that for you. There are a few reasons I did not go exactly with your set up.
1) out of respect for others hard work I do not like to take someone elses stuff and copy exactly what they did. I think in a way it is disrespectful of their hard work.
2) those gears are not easy to come by here and it really put the belt close to the mount block. I later decided to have the pulley made.
3) Through the research Al did from American Sport Bike it was not the gearing I wanted to go with and decided to keep it stock
4) I like to figure things out and sometimes its unorthodox in my technique but it works

If I offended you in anyway I truly did not mean ti.
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S1owner
Posted on Tuesday, August 08, 2017 - 05:14 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

New pulley milled down and installed. It should work perfect. Just need to sort out some dash stuff with Marc and its time to ride!







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Upthemaiden
Posted on Wednesday, August 09, 2017 - 08:37 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Pictures are upside down! I like it though, the blue pulley looks good.

I'll be curious to hear if it feels weird riding with no kind of heel plate at all. I've had passing thoughts of chopping my passenger peg brackets off, but I know sometimes I rest my heels on them, and I'm not sure if it'd feel weird with me heels just floating out there.
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S1owner
Posted on Wednesday, August 09, 2017 - 09:06 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Umm pictures look right on my phone

Have not had heal gaurds at all so I cant say if the feel is diffrent
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Brother_in_buells
Posted on Wednesday, August 09, 2017 - 09:21 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Looking good Ken ,really hope you got it fixed this time!

And the upside down pictures are a bit of Australian influence
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Hootowl
Posted on Wednesday, August 09, 2017 - 10:20 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

They look right on phone, not in PC browsers. The picture was likely taken with a phone...perhaps there's some metadata in the photo that phones understand and PC based browsers do not?
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Upthemaiden
Posted on Wednesday, August 09, 2017 - 11:12 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I just checked on my phone and they're upside down on there too. Maybe the pictures are fine and I'm just upside down.
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Hootowl
Posted on Wednesday, August 09, 2017 - 11:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

They look fine on my iPhone.
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Joesbuell
Posted on Friday, August 11, 2017 - 09:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

G'day Ken I wasn't offended mate sorry if I came across that way.
My ratio was chosen because Oz is a big place (long travel time to good twisties) and I find while its fun the 27/61 2.25 gearing is too much on bigger rides just my opinion. In Australia our bikes were way over geared 29/55 1.89 to meet A.D.R Australian design rules. common thing to do was put the US market 61 rear pulley on giving ratio 2.10 which I really liked, still grunty but comfortable on a long ride. So therefore my 26/55 2.11 is bang on the money. I put a slight chamfer on the engine/swing arm mount block as a little belt clearance and the powder coat has not a mark on it. I think from memory Purpony made your rear pulley correct me if I'm wrong. He could have made yours 55 thats all I was getting at. I bought my 26T pulley from Baker and the 135T belts genuine Buell. I made mine so that serviceability was easy in that I could buy genuine parts and not have to rely on someone to custom make service parts for me. I hope you get it sorted soon and can get it out and ride it : )

I need to get mine back on the road only need to make an exhaust mount, battery and re fit oil lines....

Cheers
Jodie
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No_rice
Posted on Friday, August 11, 2017 - 10:25 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Holy shit your alive?! ^^^^^
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Joesbuell
Posted on Friday, August 11, 2017 - 10:47 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Yes indeed Tim lol
I went through dramas at work well long story short I'm back : D
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S1owner
Posted on Saturday, August 12, 2017 - 11:10 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

JOE
We are good!!!
I might over the winter still get those gears. Would love to find an oem 55 and weld and redrill it though before spending all the $$$ on having one made.
So you did clearence the pivot block I knew you had to of done something because the 27/61 was close so the 26/55 would have hit easily.
Hopefully this works for me it is a stock belt so its easy to find.
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