Going to do a 200 rear conversion on my 2006 Custom. It might take a while because all the parts have to come by mail. As things show up I will post updates.

Step 1: Get the Bike.

Step 2: decide on what wheel type and size

Step 3: order said wheel.

I have gone with a 6X18" with 60 spokes [I like the look better than a mag]

A 200/50 x 18 will give me the same diamiter as the stock Sportster tire so no need to calabrate speedo

Step 4: unpack my new toy

Picked up another swing arm today, things are starting to come together.

hey mate.
are you using a standard swing arm? or modifying a standard swingarm?

also what are you doing with your factory solid rim?

I am planning on modifying a standard swing arm, as for the standard rear wheel I will decide after the conversion.

Modified the swing arm, fitted and spaced the disk and pulley and knocked up some temporary spacers. Still have to fit the axle adjusters and brake caliper before I can make the final axle spacers. Happy with it so far.

looking good , will be good to see when finished

The conversion is going to look great

Another part arrived today, getting closer. Step by step, little by little.

 

Hey mate..

How was the swingarm modified?? Looks like nothing has changed on it.. Looks factory still?

Glad you like it and you think it looks stock, that was the look I was after.

I was lucky enough to go on a charity ride a few months ago and met a great guy that had his show bike and his everyday ride [fat boy] there. He let me check out every detail of his 200 and 260 rear ends and with my bike parked along side it was easy to figure out what had to be done to the Sportsters rear end to get it to fit.
Everything being equal there is enough room at the front of the stock swing arm to fit a 200 rear tyre and without the rear pulley it all would fit. But not wanting a scooter I had to find a way to fit the pulley. Roughly a 200 is 2" wider than a 150, so that is an extra 1" each side. So far so good. The disk side is already wide enough to fit everything because the disk sits inboard but the pulley side is wide enough to fit the tyre but too narrow to fit the tyre and pulley. So that side has to be widened by the width of the pulley + a bit. In the factory when they make the swing arms the pulley side is bent IN from about 2" past the welded section. So I figured if it was bent out again then squared off about 7" from the rear to allow for the pulley it should give me the extra 1" I am after. I still have to set it all up and that is a bit more complicated because the new wheel has a 3/4" axle not a 1" but it is getting there.

Been busy the last couple of days, got the axle spacer "cut yourself" type which inspired me to make my own axle shaft/drive belt adjusters.

Using the disk as a base line to work from I worked out how long the spacers for each side should be the cut them to length.

This is what I have so far. Also ordered the rear tyre today.

Another piece closer, this arrived today from the USA. Still waiting for wheel and bearing shims to get the setup perfect, a 1 7/8" socket and the new tyre. They are all in the mail. I am not 100% on the rear guard yet. I would like a big FatBoy rear guard but haven't been able to find the one I want yet

A couple of bits turned up today, the tyre [at last] and a brand new 1 7/8" socket. Getting closer.

Oh the reason I don't have the tyre fitted yet is because I was working on the front end. Installed a Valcanworks + 3 deg rake kit and a set of +2" tubes.

Old tyre + New tyre

 Good stuff. Looking forward to seeing it finished. 

Unless my eyes deceive me Jinda, you've used the same professional quality method of raising the headlight to a more desirable height that I did.....

The old socket trick. Mind you, yours looks like a plug spanner, mine was a 9/16 socket I had spare.

Hey! it works, and it's shiny like chrome......

Colstah, the steal is better quality most, and as you said it is already chromed. Took it for a shake down ride today and all is good. Pushing it hard, stopping it hard, cruising, doing figure 8's, one hand, no hand, even parking. To me it didn't change the feel too much but it did seem less prone to wander at high speed and just a little bit better doing highway speed corners. So I guess I am happy with the front end and the way it handles. I will put up a few more K's just to be 100% on the front end before I put the 200 on the back.

The extra rake looks good. The +2' tubes look like they keep the frame sitting just right.

Nice that the handling is at least the same if not better.

Well done Jinda , keep the updates comin .