Ok. So 2 belt pulleys in the open transfer case with a belt? I think you would have to re work the transfer case or have something made one off. The back half of the transfer case isn't pretty and you would have a lot of extra case. It would Be interesting to see.

Yeah Musky that is exactley what I want to do. I think essentially I would have to take the transfercase off completley and have it machined down. I already want to do it to the other side where the drive pulley is. I am running the naked pulley setup but dont like the look of the extra case lip around the pulley. As long as it is a 1:1 ratio then it shouldn't be a hell of a headache to accompish. Just a new set of pulleys instead of gears. I am just wondering now is this would still be structurally sound. I think it would but that is just something I'll have to check into and see. Guess I'll just have to jump in and see. It'll be fun and interesting or complete hell. Maybe evan both . thansk for all the input guys. I greatly appreciate it.

ruffnek wrote:
Yeah Musky that is exactley what I want to do. I think essentially I would have to take the transfercase off completley and have it machined down. I already want to do it to the other side where the drive pulley is. I am running the naked pulley setup but dont like the look of the extra case lip around the pulley. As long as it is a 1:1 ratio then it shouldn't be a hell of a headache to accompish. Just a new set of pulleys instead of gears. I am just wondering now is this would still be structurally sound. I think it would but that is just something I'll have to check into and see. Guess I'll just have to jump in and see. It'll be fun and interesting or complete hell. Maybe evan both . thansk for all the input guys. I greatly appreciate it.

Dunno if you wanna cut up your existing one, but Pinwall Cycle has a t-case up for $150

Ebay

The engine to transfer case isn't a 1:1 ratio, but rather a 1.09375:1 ratio (35T on the engine, and 32T on the t-case). Eliminating this reduction ratio using two 35T sprockets would effectively be the same as running a 32T front pulley with a 64T rear pulley (if such a thing existed) which would be some pretty tall gearing.

Not sure what the numbers would be if you ran two 32T sprockets as I don't know the other numbers (the gears inside the case that mate the crank to the transmission) used in calculating the stocky primary ratio of 1.532:1.

Also, you'd be hard pressed to eliminate the transfer case all together as you'd have one heck of a long belt or chain. The distance between the two pulleys and the distance of the pivot point of the swingarm from the front pulley would likely cause too much slack in either when the suspension cycles through it's travel and result in the belt/chain coming off.

Yeah I don't want to change up the ratio any. Wanna keep it the same. So right now I'm basically looking for a Set of correct tooth pulleys and a belt to fit. Might have to do some rebudgeting for this setup But oh well I think this is gonna be fun. I am damn sure gonna give it a shot. Whiskey stock was getting real low when I left home so I will definately have to restock before I start . I'll keep yall posted and let yall know what I come up with.

Whatever you budget make sure to atleast triple that number! All the small things add up quick.

ruffnek -

Just a thought before you start unbolting stuff: you do realize that this open belt transfer case isn't going to be turning or moving at all when the bike is stopped, right? I only mention it because, while I don't care for open primaries on HD's, I do think that one of the coolest parts about them is that whenever the engine is running, that belt is out there whirrling around.....it looks dangerous .....which is also why it looks cool, IMO Yours will only be moving when the bike is in motion.

Sure. But I've never seen it done on a roadstar nor have I ever heard of being done. I now their is a guy on here warstar? i think who removed the transfer case completly. Went to a right side drive straight off the tranny. Looked cool as hell but don't know how it worked out for him. I know the belt will only turn when I let out on the clutch, but it is just something different. Have already found a couple of sites that either have HD primary pulleys or do custom pulleys but cant get a hold them till Monday. Plus it will be about three and half weeks before I get back home and can get some measurements and demensions off my bike. Looked at the transfer case on ebay Gareva1 suggested and I think it would match up without any problems but I don't want to go and start buying things untill I've got some definate measurments to work with. Right now I'm up to any and all suggestions. I definately appreciate all the replies. This will definately take a little while to bring around, but I'll definately keep yall posted on what comes of it.

Getting the pulleys painted or powdercoated to match the tins would be a nice touch I think.

Kandy purple over a metallic siver basecoat with real flames and a little tank artwork the first of June when I get back home. Can't wait. Got the barons 31T on front that will come off and get the kandy treatment. Sould have enough left over if I don't screw it up while I'm painting it to do the transfercase pulleys once I get that figured out. Thining about shooting the front fork cover at the same time but still unsure.