PRISM SUPPLY | DIY | 1991-2006 Sportster chain drive installation

Introduction

This tutorial provides a step-by-step guide on converting a 1991-2006 Sportster from belt drive to chain drive using the PRISM SUPPLY conversion kit. This process is essential for those looking to enhance performance and durability. It is recommended to have this installation performed by a trained motorcycle mechanic, but this guide will help you understand the necessary steps and components involved.

Step 1: Gather Your Tools and Components

Before starting the installation, ensure you have all the required tools and components available.

Required Components

• 23 tooth front sprocket with a special nut
• 51 tooth rear sprocket (2.25" inner diameter)
• 120 link O-ring chain with a master link
• Metal offset spacer (2.1" inner diameter, may be needed)

Tools Needed

• Socket set
• Wrench set
• Chain cutting tool
• Torque wrench
• Safety gear (gloves, glasses)

Step 2: Prepare the Motorcycle

Prepare your Sportster for the conversion process.

Steps to Prepare

1. Secure the Motorcycle: Use a motorcycle stand to keep the bike stable.
2. Remove the Belt Drive Components:
   • Take off the rear wheel.
   • Remove the belt drive pulley.
   • Make sure to keep all nuts and bolts as you will need them later.

Step 3: Install the Front Sprocket

Now, install the new front sprocket.

Installation Steps

1. Position the Sprocket: Place the 23 tooth front sprocket onto the shaft.
2. Secure the Sprocket: Use the special nut provided to fasten the sprocket securely.
3. Torque Specifications: Refer to the motorcycle manual for the correct torque specifications and use a torque wrench to tighten it.

Step 4: Install the Rear Sprocket

Next, install the rear sprocket.

Installation Steps

1. Attach the Rear Sprocket: Position the 51 tooth rear sprocket onto the rear wheel hub.
2. Fasten the Sprocket: Use the appropriate bolts to secure the sprocket to the wheel.
3. Check Alignment: Ensure that the sprocket is aligned with the front sprocket.

Step 5: Cut and Install the Chain

With the sprockets in place, it’s time to work on the chain.

Chain Installation Steps

1. Measure the Chain: Lay the chain around both sprockets to determine the correct length.
2. Cut the Chain: Use a chain cutting tool to cut the chain to the needed length.
3. Install the Chain:
   • Thread the chain through the rear sprocket and around the front sprocket.
   • Connect the ends of the chain using the master link, ensuring it is securely fastened.

Step 6: Adjust Tension and Check Alignment

Proper chain tension and alignment are crucial for optimal performance.

Adjustment Steps

1. Check Chain Tension: The chain should have a slight amount of slack. Adjust as necessary.
2. Align the Sprockets: Ensure that both front and rear sprockets are perfectly aligned.
3. Test the Installation: Spin the rear wheel to check for smooth operation.

Conclusion

Converting your Sportster from belt drive to chain drive can enhance its performance and durability. Ensure you follow each step carefully, and remember to check the alignment and tension of the chain once installed. If you're not confident in performing this installation, consult a trained motorcycle mechanic to avoid potential issues. Enjoy your ride with the new chain drive setup!