Remember, the Final Drive Belt Sprocket has left-hand threads! Use a locking tool when removing or installing the sprocket.

The Final Drive Belt Sprocket (from the transmission) must align with the Rear Wheel Sprocket, which is determined by the wheel width. The Drive Sprocket has a belt guide flange on one side only.

Pre-2004, on the outer flanged side, the center mounting splines are relatively flush with the flange face. But, on the engine side of the sprocket, the center mounting splines are recessed from the edge of the belt drive face. On 2004-later, the flange is on the engine side (with recessed splines there) and the mounting nut and lock plate are on the outer, flangeless, side.

On 1991-94 Sportsters, the flanged side of the sprocket is away from the engine. On the opposite side, between the case bearing seal (for the transmission Final Drive Shaft) and the recessed splines on the Drive Sprocket, is a spacer to fit in that recess. The width of the splines in contact with the Final Drive Shaft is 0.5“.

On the 1995-03 models, the center spline contact area of the Drive Sprocket (to the Final Drive Shaft) was widened to 0.766” and the recess spacer was reduced accordingly. The flanged side of the sprocket is still away from the engine. (As a set, the seal, spacer & sprocket from 1995 can be retrofitted back to the 1991-94 models.)

Note: To fit a 1995-03 pulley to a 1991-1994 model requires the matching seal. The '95+ spacer has a larger outside diameter than the 1991-94. Also note, that 1994 was a transition year to the later style pulley; “early” '94s had “early” pulley setups, “late” '94s had '95+ pulley setups.

On the 2004-later models, the Drive Sprocket design was reversed. The flanged side was placed toward the engine, thereby pushing the usable belt surface farther away from the engine to allow for a wider rear tire (150mm). On the flanged side, the center mounting splines are recessed .40“ from the flange face.

For 2004-2005, the older spacer (as used on '95-'03) between the case bearing seal and the sprocket was still used. However, on the 2006+ models, the spacer was incorporated into the transmission output shaft bearing.

Note: The early trans pulleys will not mount to the '04-up's (even with the flange turned inboard) because:

• 1) the “extra” 1/4” for the inner spline is only a “bump”, there is no area for the nut and lockplate on the early versions.
• 2) The splines need to be recessed .40“ from the (now inboard) belt flange - they are not recessed on the early versions.
• 3) With the flange outboard, the early version Final Drive Sprocket cannot be properly aligned with the 2004+ Rear Wheel Sprocket. If the belt rides against the flange, overheating may occur and the flange (press fitted) can separate from the sprocket.

This XLForum Thread was used for collecting the above information. Thanks to those who contributed, especially Sirrom1.

1991-92 883 Deluxe
1993-94E 883 All

1994L-2003 883 All

2004-06 883 All

2007-2010 - 883

2011+ - 883

1991-94E - 1200

1994L-03 - 1200

2004-06 - 1200

2007+ - 1200

• 40110-89 - HD offered a 4-speed chain-to-belt conversion kit
• … but stopped offering them in 2005
• 40111-91A - HD offered a 5-speed chain-to-belt conversion kit
• … but stopped offering them in 2005
• PBI Sprocket #280 is for pre-belt drives and has
• … overall width of 0.85“ and offset of 0.5” with a Spline Width of 0.5“

• Reference:
• http://xlforum.net/vbportal/forums/showthread.php?t=1931756