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if its chain, try different sprockets, bigger front will give lower rpms ,and pull longer ,and be faster
if you go rear, smaller will lower rpms, and be faster, bigger rear will be quicker but top speed will not be as fast not sure if there is a speed sensor , that needs to be changed, i have the same bike, and am wanting the bigger front pully stock is 29 i think , and there is a 30,and a 32 tooth pully for the belt drive models! sweet product , not belt change either!, but like i said i read something about a speed sensor that needs something to correct it
I would think that you'd have to at least replace everything from the swingarm back but this may result in a misalignment of the front and rear final drive belt pullies. There's more to installing a fat tire than simply cramming it under there. Harley may have went to the narrower belt on the Sporty like they did on the Big Twins. Having never done this, I'm really not in a position to advise you on it.
The best way to do this is to measure the belt tension adjuster bolts on either side of the swing arm. They should both measure the same. When adjusting the belt, get both bolts at the same measurement. Then adjust the bolt to push the tire to the rear the same on each side at a time. Like if you turn the right bolt a quarter turn, do the same with the left side bolt. Always adjust the bolt pushing the axle to the rear. If you get the belt too tight, loosen the bolts at least two turns, bump the wheel forward and start going backwards again, this time in smaller increments. Once you are finished, the two bolts should measure the same length. This almost guarantees that the axle is 90° of the centerline of the bike.
Seems to me that you '93 model bike had axles that are 3/4 inch in diameter. The 2000 and later bikes went to a 1 inch axle. This would mean that you would have to machine your swingarm for the larger axle and I don't think there is enough "meat" in that area to do this safely. If he '05 wheel comes with the rear pulley, it too will be useless as the belt was narrower. You may can change the front pulley to match it but that's a LOT of work. Why don't you try to find a rear wheel off of a '90's model Fatboy?
To change the final drive belt on a Sportster is much simpler than doing the same job on a Big Twin Harley.
Support the bike so that you can remove the rear wheel, right rear shock absorber, the belt guard, and the front pulley cover. Take the old belt off and install the new one. Put the bike back together and adjust the belt to have about a 1/2" up and down movement in the middle of the belt with 10 pounds of force applied. Make sure your rear brakes work properly before you ride the bike.
While installing the belt, do not bend the belt in a radius any smaller than 4". Bending the belt too tightly will damage the cords inside the belt and may cause premature failure of the belt.
Hi Steelemazz, try giving the nice folks at J&P Cycle a call 800-318-4823 I'm sure they can come up with the right answer, for more information about your question please visit the website below. Good luck and have nice day. Harley Davidson Pulleys Sprockets