Noticed that the teeth on Rear Pulley number 3 on my Uly looking about 1/2 worn (been 2 years and about 5000 miles since I changed it) so started a search for a replacement. Luckily got a lightly used one for about £35 from fleabay plus the same ( ) in delivery from the Wannabe Republic of Trump.
Not sure why so much wear on mine, the FS Tensioner is set quite soft.

Having looked at the cost of new one (circa 200 smackers) am set to wondering, who/where would have the facility/skill to start knocking up suitably priced replacements?

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Buell owners should be committed (but not for life)

Well. You'd need someone with very good machining/cad skills. A very well stocked machine shop. It would probably help if they were a buell enthusiast.
Erm anyone we know fit that sort of bill. Andy Though i would have thought they would come in at well over 200 quid for one machined from a piece of billet a little larger than the pulley.

Are you a beach racer?
Anyone else 'worn out' a pulley (let alone three...)...?
With respect, maybe you should ask yourself what you're doing different to anyone else... or question your definition of 'worn'...

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'98 M2 Razorback, it's a keeper.

ive made a few from billet 7075... material and hardcoating is fairly expensive from the get go.

on my personal one i powdercoated black over the hardcoat.

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-"Slightly" Modded '99 X1
-620rwhp Twin Turbo '89 Mustang Coupe
-Lifted V8 4x4 Ford Explorer
-Twin Turbo AWD Ford Flex Limited

going to do a new pulley for my spoked wheels... this is one idea im toying with

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-"Slightly" Modded '99 X1
-620rwhp Twin Turbo '89 Mustang Coupe
-Lifted V8 4x4 Ford Explorer
-Twin Turbo AWD Ford Flex Limited

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Wear the fox hat

Looks like one will be available as soon as he machines up his new ones.

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Bob Krzeszkiewicz
2012 XR1200X - 2011 Kawasaki Z1000SX - 1999 Buell X1

Thanks Dave, your right, £200 wouldn't do it for me on a one off pulley, strikes me perpony has done all the hard work here, ask him how much.

Andy

Are you running tubes in those wheels or have you done a pseudo tubeless conversion, like MTBers do with the mountain bikes (Stan's No Tubes)?

All I know is $3500 is a huge chunk to buy into some of those gorgeous Kineos.

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Bob Krzeszkiewicz
2012 XR1200X - 2011 Kawasaki Z1000SX - 1999 Buell X1

Do you have anyone that can FEA that for you?

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Bob Krzeszkiewicz
2012 XR1200X - 2011 Kawasaki Z1000SX - 1999 Buell X1

My thinking too. Maybe he thinks scars and dings in the tooth roots is considered wear. I've never heard of a worn out pulley before. Does it even really happen?

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Bob Krzeszkiewicz
2012 XR1200X - 2011 Kawasaki Z1000SX - 1999 Buell X1

Is that how much they are

Those aren't Kineos on his bike. This is:

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Bob Krzeszkiewicz
2012 XR1200X - 2011 Kawasaki Z1000SX - 1999 Buell X1

Nope, definitely not a beach racer, not even a road racer LOL
Worn, the teeth lose material so that eventually resemble sharks teeth and associated belt failure ensues.

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Buell owners should be committed (but not for life)

Yes.. I have a good fried that does FEA and will be checking the pulley for me. As for my wheels.. they are tubeless. They are Alpina wheels. New they listed for 3500.... but are discontinued. I bought them new for $1000

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-"Slightly" Modded '99 X1
-620rwhp Twin Turbo '89 Mustang Coupe
-Lifted V8 4x4 Ford Explorer
-Twin Turbo AWD Ford Flex Limited