Some of you may have run across my posts in the fat tire thread, I'm in process of installing a 200 Avon on my 2002 Fatboy....WITH the original width size belt (1 1/8") for my model year. Anyway, here is my progress this weekend, I had to do the usual lawn mowing stuff and everything else before I could start, and I didn't stay focused on this the whole weekend due to I had other things going on also.

My previous pix' were the dry fit as such I could measure for axle spacers, front and rear, and plan.




So I mount the front permanently with the new spacers that came in. I needed to start with something easy first.
It went on without a hitch, I took it out for a spin because I could.



Next I tear into the primary. Why? Because I'm also changing the gearing, I'm gearing up. My OEM pulley was a 70T, my new billet pulley is 65T. That means a new shorter belt is needed. I ordered a new Gates Polychain (same brand that comes from the MoCo) I have never given much thought as to the level of time or difficulty to replace a Harley belt .
Well, it 'taint easy, not really hard either, just takes time and the right tools.

Here is the removed clutch basket, pri. chain and compensator.



And the empty primary case



So for the primary case to pop off, I'll take the starter jackshaft off, and the bolts holding the case on.
Sounds easy...but nooooooooooooo.....The TWO starter mounting bolts have to come out, and the manual says the freakin oil tank has to come off to get to the starter bolts...No Way!.....I WASN'T going to drain oil, disassemble oil lines and remove the tank without a good attempt at those starter bolts first. One bolt I couldn't even see....

Well, I did it. An assortment of pieced together extensions of different sizes and got to it. Here is the primary totally off.



So I might as well mount up the back tire now, because I have to deal with installing the new belt.
Now this is a really sad picture. No wheel, no guts, just a naked piece of what was a streetable Fatboy just a few hours ago.


OK moving right along here, it's starting to look like something again other than an eBay basket case. New belt, new rim, new tire, new spacers



And another view, because I don't plan on doing this again anytime soon. (Hopefully....please new Gates belt, please don't fail me anytime soon...)



And my final knock-off time picture, primary back intact. You can see the sun beating into the garage now. It must have been 90 deg plus today. Time for a shower and a beer, and dinner.

More later from Chop's garage.

 

so your saying a 200 will fit with the stock belt and swingarm?

thats good news

i can see the frame horns had to be trimmed

excellent thread!

this should become a sticky at the top of the page if all works out

what about the caliper and such?

 

I'm impressed, chops! My guess is you thought through this mod a thousand times before starting-and it will pay off. Keep up the pics/tips/awshits.

 

Great.I also have an 02,but always heard i could'nt put a wider tire without major changes.

 

Hey Chops, great job of documenting so many steps with such good quality photos. I can't wait for the next installment!

-Randy

 

Hi chops, what clearance have you belt to tyre??

 

6mm (.250") from belt to widest part of tire.

Custom rear fender ordered Monday, with about an 8 day lead/fabrication time so states the factory.

Should have a fender in about 2-3 weeks, next installment on this build will be dry fit fender-lights, then paint.

I haven't buttoned up the primary yet, I wanted to give the threadlocker ample time to cure on the clutch and comp nuts before I took it out for a spin, plus I have a day job.

 

what spacers did you use to get these clearances?

 

The belt-to-tire clearance is a by product of hub and pulley design.
Even though spacers are made for the pulley, I am not using a spacer between the wheel hub and pulley.

 

ah i see, what hub are you using?

this may turn into a winter project for myself

i assume you mean hub as on the rear wheel

not as in the primary?

did this shift the rear wheel left?