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Well… I finally did it. After purchasing the Scootworks Overdrive Pulley this past August, I installed it and would like to share my impression so far. I did a 275 ride today and was able to put it through its paces. This evaluation is only my opinion and is based on no more professional or scientific data other than the mere fact I like to ride (so what else is there).

Installation: This was the main and only reason I waited so long to put this thing on my Vulcan. I was reluctant from the perspective mostly of the thought of moving the rear wheel to set the belt tension. My fear was unfounded. The only part I really struggled with was loosening the bolt on the OEM pulley. This should be done before placing the bike on the motorcycle lift (They had a nice one on sale at Harbor Freight for about $80). I had to loosen the rear wheel bolt and move it forward to get the pulley off and install the new one. Remember to flatten the lock-ring flange before attempting to loosen it and to crimp it once the bolt is replaced. It toke me just over an hour to do the whole job. The belt tension was pretty taut so I just adjusted the rear wheel to what felt like the same tension. It worked OK as I didn’t experience any noise and/or other problems. I was really careful that the wheel was as straight as possible.

Running the Gears: Starting out in first was a pleasant surprise. Some have stated thet it took a little more juice getting out the gate. I found this to not be true. As a matter of fact the bike seems to pull out better than before. The first gear on this bike strikes me as being under geared, leaving me with the feeling of needing to do a quick shift at a low speed. First seems more useful, as does all five gears. It seems better suited for the way I ride. I still use fifth on city streets, but not nearly as much. Forth gear is now a very usable gear for speeds under 45 mph. The changes in the way the gears feel will take a little time to adjust, but in a pleasant way. The bike seems peppy going through the gears (bear in mind I have a K&N air filter and Cobra 2 into 1 Power Pro pipes. The gearing gives more juice to this set-up).

The Freeway: This is where this pulley really excels. After getting on the freeway, I was left with the feeling of needing a sixth gear at about 60 mph (real speed). Not now. The bike wants to run and does so much more comfortable on the freeway. I don’t feel the need for sixth nearly as much (if at all). At 70 mph, the engine is running almost 500 rpm’s slower and seems less strained.

The Numbers: First the best news of all. My speedometer before was running almost 10% high. At 70 mph, it is within ½ mph with my GPS (Garmin Nuvi 650). No more “doing the math” to figure out how fast I‘m going. Before my odometer was reading about 4% high compared to my GPS. It’s now 3.5% below so I figure that somewhere about 24K miles, there will be a brief moment of total truth. This is still within federal standards. No need to use a Speedohealer or a larger tire to correct the stats. Now here’s the weird thing. My tachometer still matches the speeds on the speedometer (IE 3000 rpm at 55 mph in 5th gear). This totally baffled me until I realized, the speeds being shown on the speedometer are about 9% lower. What this means id before that same 3000 rpm’s was only moving me at 50 mph in real time, adding 5 mph to the speed of the motor. How kewl is that? This will also affect the perceived mileage with the change in the odometer.

Final Words: The pulley exceeded my expectations. It feels like it has more juice. This helped with both the freeway as well as in the twisties. I believe I will get more longevity out of the motor as I can tell it does definitely not have to work as hard as before. I believe I got the belt tension and wheel alignment pretty right-on as there is no noise or other adversely notable problems. Only time will tell. I believe the person who posted “WARNING” had an isolated experience. This pulley rocks!!! I seriously doubt that I will replace the rear pulley as the feeling is so well and the numbers look too bloody good to mess with. I hope this evaluation and information will help some of you out there with your decision as to whether or not to do this mod. Good luck and let the discussion begin!!!:D:cool:
 

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Thanks, Rollingbones. I've been wanting to do the pulley changeout too, and was seriously thinking of doing them both at the same time; after reading your review, i'll stick to just the front at first and save a pile of cash.

Did you notice a change in clearance for the tire and the splash guard? That was my main concern about doing just the front - i was afraid it would pull the tire too far forward.
 

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Thanks, Rollingbones. I've been wanting to do the pulley changeout too, and was seriously thinking of doing them both at the same time; after reading your review, i'll stick to just the front at first and save a pile of cash.

Did you notice a change in clearance for the tire and the splash guard? That was my main concern about doing just the front - i was afraid it would pull the tire too far forward.
This is my only remaining concern as well, as on my custom, the wheel already looks like it's set a bit too far forward as it is. I was planning on purchasing a larger wheel to compensate for that, and/or installing a rear pulley instead, but WOW, the cost difference!!!

Let us know your continued experience, Bones, and a huge THANK YOU for posting this review! I'm practically convinced now! Perhaps I'll just have to go for the pulley, a slightly larger tire, and pull the splash guard? LOL
 

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I installed the front pulley on mine last summer and i have to agree with everything Bones has said.

You do have to move the rear wheel forward but it is less than 1/2", i have has no clearance problems even running 2up. Granted, the wheel looks like it is too far forward but it actually isn't.

If you don't have the front pulley installed, you don't know what you're missing, as i've said before, the 900 should have been geared like this from the factory.
 

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Nice write up. I thought about the pulley but ran into a few issues: 1) Cost; 2) Lowering kit 2" drop with Avon 200 already hits the splash shield on bumps (even after a lot of trimming; 3) Rear pulley-again cost. Since the new outboard I'm looking at for my boat costs more than my Custom the bike is going on a diet this year.
 

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Discussion Starter #6
I have no issues with wheel clearance. I took a look up under the wheel well. While the wheel does move slightly forward, it looks like only about an 1/8 to 1/4 inch of clearance is lost with the inner splash guard at the front of the wheel. We went over some pretty bumpy roads yesterday and I didn't see any signs of rubbing anywhere so it looks good at this time. I can't vouch for the custom since I have the classic version.
If (and I say "if") you were to add the rear pulley, you would regain the clearance as the OD rear pulley is smaller than the OEM, but like I said, the numbers would be way off again. As for using the pulley with a lowering kit, I don't think that would work very well unless you removed the inner splash guard (not a good idea) or replaced both pulleys. so deciding between lowering or gear/speed adjustment and accuracy may be a matter of priorities.
I know a new larger tire is one answer, but they're more expensive than the stock size. By the time you get to the third wheel, the savings would be lost and then it would be more expensive in the longer run of things. I hope this helps. Can't wait to ride again all day!!!
 

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2) Lowering kit 2" drop with Avon 200 already hits the splash shield on bumps (even after a lot of trimming.
Does the Avon 200 have a larger center circumference than the stock Dunlap? Seems like i remember seeing that it does. My bike is also lowered 2", so hearing about your's rubbing concerns me a bit. Especially with aaron saying it moves up 1/2". That seems like a BIG move to me.

I'm about to go to the "darkside" on mine, and i think the center circumference, or rolling diameter, is about the same or slightly less, so i may have a bit more room to work with (hopefully). I've already bought my tire and was going to do the pulleys (pulley now, thanks to Rollingbones) and tire at the same time.
 

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Does the Avon 200 have a larger center circumference than the stock Dunlap? Seems like i remember seeing that it does. My bike is also lowered 2", so hearing about your's rubbing concerns me a bit. Especially with aaron saying it moves up 1/2". That seems like a BIG move to me.

I'm about to go to the "darkside" on mine, and i think the center circumference, or rolling diameter, is about the same or slightly less, so i may have a bit more room to work with (hopefully). I've already bought my tire and was going to do the pulleys (pulley now, thanks to Rollingbones) and tire at the same time.
The Avon Venom 200/70/15 is about 1-1/2" taller than the stock Lop. I'll be checking tire circumference on my next tire. Not exactly what I was expecting but it's held up almost 7k miles with plenty to go. I may switch to the 200 Metzler next time - it's not as tall. The inner splash shield needed trimming across the mounting bolts when I lowered the rear 2" but it's easy to do - but it rubs at potholes with the shock set on #5 (I weigh 168).
 

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Good review. I hope I can get my hand on one soon.
 

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Well… I finally did it. After purchasing the Scootworks Overdrive Pulley this past August, I installed it and would like to share my impression so far. I did a 275 ride today and was able to put it through its paces. This evaluation is only my opinion and is based on no more professional or scientific data other than the mere fact I like to ride (so what else is there).

Installation: This was the main and only reason I waited so long to put this thing on my Vulcan. I was reluctant from the perspective mostly of the thought of moving the rear wheel to set the belt tension. My fear was unfounded. The only part I really struggled with was loosening the bolt on the OEM pulley. This should be done before placing the bike on the motorcycle lift (They had a nice one on sale at Harbor Freight for about $80). I had to loosen the rear wheel bolt and move it forward to get the pulley off and install the new one. Remember to flatten the lock-ring flange before attempting to loosen it and to crimp it once the bolt is replaced. It toke me just over an hour to do the whole job. The belt tension was pretty taut so I just adjusted the rear wheel to what felt like the same tension. It worked OK as I didn’t experience any noise and/or other problems. I was really careful that the wheel was as straight as possible.

Running the Gears: Starting out in first was a pleasant surprise. Some have stated thet it took a little more juice getting out the gate. I found this to not be true. As a matter of fact the bike seems to pull out better than before. The first gear on this bike strikes me as being under geared, leaving me with the feeling of needing to do a quick shift at a low speed. First seems more useful, as does all five gears. It seems better suited for the way I ride. I still use fifth on city streets, but not nearly as much. Forth gear is now a very usable gear for speeds under 45 mph. The changes in the way the gears feel will take a little time to adjust, but in a pleasant way. The bike seems peppy going through the gears (bear in mind I have a K&N air filter and Cobra 2 into 1 Power Pro pipes. The gearing gives more juice to this set-up).

The Freeway: This is where this pulley really excels. After getting on the freeway, I was left with the feeling of needing a sixth gear at about 60 mph (real speed). Not now. The bike wants to run and does so much more comfortable on the freeway. I don’t feel the need for sixth nearly as much (if at all). At 70 mph, the engine is running almost 500 rpm’s slower and seems less strained.

The Numbers: First the best news of all. My speedometer before was running almost 10% high. At 70 mph, it is within ½ mph with my GPS (Garmin Nuvi 650). No more “doing the math” to figure out how fast I‘m going. Before my odometer was reading about 4% high compared to my GPS. It’s now 3.5% below so I figure that somewhere about 24K miles, there will be a brief moment of total truth. This is still within federal standards. No need to use a Speedohealer or a larger tire to correct the stats. Now here’s the weird thing. My tachometer still matches the speeds on the speedometer (IE 3000 rpm at 55 mph in 5th gear). This totally baffled me until I realized, the speeds being shown on the speedometer are about 9% lower. What this means id before that same 3000 rpm’s was only moving me at 50 mph in real time, adding 5 mph to the speed of the motor. How kewl is that? This will also affect the perceived mileage with the change in the odometer.

Final Words: The pulley exceeded my expectations. It feels like it has more juice. This helped with both the freeway as well as in the twisties. I believe I will get more longevity out of the motor as I can tell it does definitely not have to work as hard as before. I believe I got the belt tension and wheel alignment pretty right-on as there is no noise or other adversely notable problems. Only time will tell. I believe the person who posted “WARNING” had an isolated experience. This pulley rocks!!! I seriously doubt that I will replace the rear pulley as the feeling is so well and the numbers look too bloody good to mess with. I hope this evaluation and information will help some of you out there with your decision as to whether or not to do this mod. Good luck and let the discussion begin!!!:D:cool:
Bones, I see you mentioned a K&N air filter installed on your machine. I didn't think it was available for an '08. Can you clue me in on how/what to do?
 

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Discussion Starter #11
I bought a new Chevy Silverado a few years back and installed a K&N filter. Later I replaced it with a FIPK cold air intake (sweet set-up). I found the filter I had left over so I carefully cut it to fit the frame of my OEM filter, sealed it with black roofing sealant and installed it. It seems to work great and I savee about $30 every 4000-6000 miles. Here's a couple of pics:
 

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Nice post. I too find myself wanting to shift into 6th @ 60mph. Had my doubts about the pully after the "WARNING" post. Thanks!
 

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Mark,

Thanks for the detailed review on the pulley. I think that might put a lot of people at rest. I know that after the "Warning" post came out I was starting to hesitate on weather or not I would like to make the change.

One quick question for you or anyone else that has made the change. Is the stock Kawasaki pulley made from steel or aluminum?
 

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Discussion Starter #15 (Edited)
The stock pulley is made from steel while the OD pulley is machined aluminum. I plan to wait about 2-3 weeks of use and remove the two covers and inspect to see how everything looks. Of course I'll report back here with what I find. I want people to know an un -biased truth as to what I'm experiencing and so far it's all been positive, but will let everyone know the minute when and if I run into any problems. The key is to read the instructions and follow them carefully. The only change is to not put the bike up on the lift until everything is loosened enough to not cause any problems while it's up in the air and even then I only lifted it enough to clear the wheel and use the locking lever on the stand (keeps the hydrolic from slipping and lowering the bike unexpectedly. I'm also keeping a close eye on the rear wheel to make sure it doesn't move. I also recommend you us a torque wrench to tighten down the pulley nut (90-110 ft/lbs), wear mechanic's gloves and safety goggles. The nut needs to be pretty tight.

For those of you who have been on the fence about doing this mod, I suggest you wait until I can inspect everything a couple of weeks from now, just to be sure. Of course I don't accept any responsibility for what anyone else decides to do or does. That being said, I'm very happy with the results thus far.

As a side note, I changed my oil a couple of days after installing the pulley (Mobil 1 full synthetic and a K&N oil filter) and used the bike lift for that as well. It really make things a lot easier so the lift will have many uses down the road. I also expect to save money as now I can also pull my own wheels and take them in for tire replacements, saving even more money. Life is good on a Vulcan!!!
 

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For the time I had my 900C (lost it on accident, now on a 1600) the front pulley was the best money I spent on it. Easy install, I never had any problems with noise, and the gearing seemed perfect (to my driving). I did notice you had to accelerate a bit more on takeoff, but so minimal it made no diff to me. Never had any clearance issues with stock tires.

Also the change is soo good I see no reason why spend all that money on the rear pulley.

Unfortunately, the pulley went on the bike to the insurance. I still have the OEM one, if anybody ever needs one. :)
 

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I'll just add that I put this pulley on my bike last summer and was very pleased with the results. I pull a small trailer and I was concerned about loss of power but I found no noticeable difference when towing.
 

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It's been a few weeks now Bones... any updates?? :D
 

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Bones thank you so much for the review. I just saw it today and i am once again excited about receiving mine. Ordered mine a month ago, man i wished Debbie would watch this forum and still have not heard squat from them, i fear i have been taken. But I will give it a little more time until the bank account comes backup up then I will start looking elsewhere, rider here in my area found one on Ebay for 120, grrrrrrrr, and I invited him to make use of my air powered impact wrench which i have read really helps.

Looks like you and I are great minds running on the same track as I have a lot of the same mods is there any thing better than the COBRA 2-1, I think not.

BigMoe:
I am almost ready to pull the trigger on a hidden hitch as I mentioned bank account, MrClean told me he has had no problem with the CT tire and the hitch which is great as I will not go back to MC tire ever again, even if I have to purchase a tire repair shop:D.
Yes I have found the Ebay site and bookmarked, want to thank you for doing us all a favor and producing them for us, you are an EXCELLENT FELLOW

To all who will listen PLease check out a thread i posted on a tech I just discovered, and I am a Techno Geek, search for woodgas and indulge me for a short while I hope you will be as blown away as I was, for sure, for sure, yup, yup, good stuff there.
 

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Uh, I put the Scootworks pulley in fall of 2007. Took it off last December? when I put my hidden hitch on. Why? Well, I wanted to check and see fi there was any wear as I'd heard all sorts of horror stories. I also wanted to see if I'd notice it now that I've got a couple years of experience on the bike. Back then I just had 5 months.

Yes, I noticed the difference. Oh the bike runs fine but it does take more rapping to get down the highway. And the speedo being so far off is just a pain, I've got paint marks on the speedo cover to show me where I should be driving, even those of off when you consider just a smidge over 55 mph is actually 50 mph 60 mph is acually 54 and so on The only accurate measurement is 100 mph which is 90 on the money. What a pain in the rump and the marks look tachy even if they are effecient.

There was no wear what-so-ever. I reckon whoever had problems maybe didn't get things cinched down right or didn't get the locking washer attached. In any case, I didn't have any problems. Next time I get the wheel up in the air I'll put the Scoots pulley back on.

Now granted, when I first put the Scoots pulley on October of 2007, I finished the job just about dark and I took it for a ride to feel it out. Even though I had only been riding for about 5 months I was so enthused with the pulley that the little jaunt I took got me home about midnight. My wife was a little peeved. Seems I didn't have my phone on vibrate and couldn't here it in the breeze. Where did those hours go so quickly? Beats me, but I had to stop at the gas station on the way to work and I could just SWEAR I had a full tank. Oh well. Once you know how to do the install it only takes about half an hour start to finish.

Did I mention I'll be putting it back on?

Make sure, when you do the install, put grease between the pulley, the lock washer and the nut. Maybe those folks aren't doing that and they're getting an artificially high reading on their torque wrenches.
 
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