Has anyone changed front pulley on a 1998 1200 custom. Stock is 29teeth and am considering a 31 or 32 pulley. problem trying to purchase larger than 30 tooth. Any info appreciated.

 

Gearing changes are going to be A LOT easier if you switch to chain. That being said, if you have the option to go down a tooth in the rear(which is unlikely) you should just try the 30 tooth on its own. That will make a difference. If you gear it too low you are going to sacrifice low end power and lug the motor down, possibly crack ringlands or bottom of jugs
And unless you have a high perf. Motor, running with the 30 tooth at 65-70 mphs is fine for the motor. Just change your oil a little more frequently

 

Another MAYBE viable option would be to change the primary gearing, engine sprocket (like 35t to 38t) plus primary chain to match ...this would accomplish the same thing and not cause a speedo error. About $175 list price to do this...
might be too much of a change at about 8% though, as was said gearing the bike too tall is not so good.
see http://sportsterpedia.com/doku.php/t...vo:priclutch02 for specs on what was used on various years and models

 

Why do you want to go 31/32? What rpm’s are you pulling now? Do you have a tachometer? Is your engine a relatively stock bike producing 65 ish hp?

 

BTW an excellent site for checking out and comparing various gearing setups in advance is https://www.gearingcommander.com/

(and don't neglect to check out the repeat contact numbers for a chain final drive, FWIW I learned that one the hard way (on a Ducati)...the odds of installing a bad combo are low but it happened to me and that meant noise, vibration, and extremely rapid wear)

 

Read sig.I have zero problems with lag,lug,or anything else.I can cruise at 70 in 4th for around 3600,....85 in 5th at 3500'ish and 90 at 3789.I built mine for Hwy and interstate and it does great.I never lug the engine.

 

with just the stock 1200,the 32 tooth for your application will probably be too tall.31 will probably be fine.

 

https://www.883sportster.com/whichpulley

 

If you go up one tooth on a 883 front pulley, can this be done using stock drive belt? (28 tooth to 29 tooth)

 

I have a 31 tooth pulley up front and think it's just great. Changing my 68 tooth rear to a 66 tooth rear as well...

I have a Stage One 2016 Forty Eight...