I have a 2001 XLH1200, I recently found an article by Chuck Hawks that recommends changing out the 61 tooth rear drive pulley for a 55 tooth one. This will lower the rpms at speed and keep the vibration down at 60-65 so It will be smoother. I can't get anyone to tell me where to find this Pulley, HD won't give me any suggestions, I need to know if I will need to also change out the drive belt, and is there an HD number for the pulley? Anyone out there got an answer? Supermax has a pulley with 58 teeth, but it is way too pricey. One local shop can get a 55 tooth pulley, but he will not guarantee the fit or results.

 

Check out the HDI pulley it is smaller than the stock one, it may be 55 tooth. You will also need the HDI belt. The HDI speedometer or a recalibrator like S & S or Dakota Digital will get the MPH right. You will also need a different belt guard. Hope this helps.

 

I did the pulley on my 97' Sportster, you will need a different drivebelt also. I bought it through Sturdyke, it's been a while. If you could find the part number Zannotti would have a good price. If you do the conversion, you will not have the same power you have now, most notably upon takeoff in 1st gear. When I did it, I also did cams, heads, pistons and exhaust. Also have to adjust the VOES until the pinging is gone when youre taking off. The highway revs were nice but with a constant 55 - 60 mph, I never felt like I was in the right gear. You lose about 17% of your power you had before the pulley change. It ran about $200, plus a speedometer recalibrator(Dakota Digital). I will try to find the part number, like I said, it's been a while. Good luck.

 

HI:
I offer 31 & 32 tooth front and 66 rear pulleys for Sportsters.
For the 2004 -UP 883's it gives you the same final gear ratio as a 29 tooth on a 1200. The 32 requires some modification to the mounting posts on the pulley cover and to the exhaust bracket, the 31 does not.
The other way to get there on '04's+ is to change the engine primary sprocket and chain. The advantage here is that your speedometer will be correct (factory). If you install a 32 tooth the speedometer is "slow" by about 14%. The EFI units can have the ECM reprogrammed at the dealer, or any year can use a "Corrector" that allows any time changes.
For the 2003 and earlier models it gets you the same final ratio as the 55 tooth rear but you don't need to change the belt, and it is readily available. You can read about it, see installation pictures and testimonials from other riders on the website: 883Sportster.com
You can also download a pdf showing all years and pulleys with the rpm and mph change for each pulley and model.