My '90 1200 is a big high on the highway, so I've considered changing either the tranny sprocket or the rear wheel sprocket. I looked on JP Cycles but they list my bike as having a chain, and it does not. I plan on removing the rear wheel to swap the tire out this weekend, so I'd like to have my plans in order. Which gear do I swap? What size do I want? I don't want to kill my low end, I'm 175lbs and my wife is 110.

Thanks.

 

I did a quick search and what I found said that in 1991 they went from a 4 speed to a 5 speed and switched from chain to belt drive. "Sounds" like it was previously converted from chain to belt.

1991 Sportster:
5 speed tranny replaced the 4 speed
Belt drive replaced chain on 883 deluxe and 1200 models

 

Previous owner is the original owner, said the bike is exactly like it came. Considering the mileage, the original air filter and tires, I highly doubt he changed to belt. And it's a 4spd.

 

I am not trying to argue with you since it's your bike.
But all the info I can find says it changed in 1991. I don't doubt it is a 4 speed and belt driven.
Look here Wiki-Sportster
Look at the Significant changes by model year section.

And here Sportster-History


To make sure you get the pulley you want, you might want to count the teeth on the pulleys and see what is available for upgrade options that wouldn't require a belt change.

Good Luck

 

Oh, I know, sorry if I came across combative. I went to the stealership today and they insisted that the bike came with a chain as well. Here's the comical exchange.

I told the guy "Listen. The bike was bought here. Right here. 22 years ago. Do you really think a guy that has the ORIGINAL tires and air filter in 1900 miles would have swapped the belt from the chain? No." "Well, he must have bought it in late 90 and it's really a 1991." "No. It's a 90. Here's the VIN." "You're right...it's a 90. It must be a late '90 with '91 parts." "No. It was bought in early 1990 and it has a 4 speed." "Well, you got me, then!"

The original owner told me that when he bought it the then owner of Ft. Lauderdale Harley told him it was some sort of 1 of 1000 bikes, specifically 400 something or other. Doesn't remember exactly what, but the dealer specifically mentioned the belt. I sure as heck don't know.

Either way, short of pulling the sprocket and bringing it in to match up, nobody knows what to look at for it. Very odd!

 

My buddy bought a 1990 883, and had it converted to a 1200, plus the drive belt kit installed before he even picked it up. The drive belt kit was sold as an accessory for the XL series back then.

I ordered and waited for a 1991 883 instead, first year with the 5 speed tranny, and the next to last year the standard XLH came with a chain. I believe I was the first to receive a "standard" 1991 XLH in all of Los Angeles County at the time. Ordered in August 1990, picked it up the day after Thanksgiving 1990.

In 1991, the 883 and 1200 series (except the bare "standard" XLH) all came with the "newfangled rubber bandy thingy." My standard model with chain was already not as popular a choice, hence the long wait for it to arrive.

Not sure what your meaning of "big high" is, but if it's geared "too high", I believe you can buy a smaller front belt sprocket, or conversely, buy a bigger rear sprocket.

John

 

I wonder if my bike had the accessory belt conversion installed by the dealer while it was on the showroom and the previous owner never knew it wasn't factory? It'd sure make sense, though I'm not sure why the dealer would do that. Does Harley keep any sort of information on these old bikes to know how they were delivered? I'd like to find out what the dealer meant by 1 of 1,000.

John, I mean just the opposite...gears are short, I want them taller. Larger front or smaller rear, but nobody seems to want to say that the parts are available, since it doesn't exist in the HD books, and the folks I've spoken to think the 4 speed sprocket will differ from the 5.

 

My 1991 sevice manual lists a 29 tooth front belt sprocket for the 1200, and a 27 tooth sprocket for the 883 Deluxe. Rear sprockets are the same at 61 teeth.

Hope this helps out a bit.

John

 

Hmmm, so I'd need to get a 30 or 31 tooth, which may not be that easy to find up front, or a 59-60 out back. I had hoped to do this while the rear wheel was off, but I may just have to deal for now until I get it figured it out. Plus at $200 a gear, unless I found a good used one, it's a pricey endeavor.

 

OH so glad to have found this as I am about to try to change the transmission in the hubby's 1990 4 speed chain driven sportster to a 5 speed belt driven from a 1991. We would love to keep it chain driven if that is even possible. Anyway, I don't want to crack the case I basically want to slide out the old trans and slip in the new one but I dont know if this will be possible. I am also struggeling to find out what sprokets I will need in order to go with the belt. I am really working on this myself with help from some of his friends as a surprise since his bike went down so ay info would be helpful so I can have everything here and ready for them.