I remember how difficult I thought this swap was going to be, way back when I too was a dumb no0b.
then I did it.
not bad at all.
and also, since I'm so fuckin nice I answered all but one of your questions.
now start buyin parts so I don't feel like I wasted my time.
[but really, it's stupid simple. esp without the rear brake. buy axle, wheel, tire, and sprocket (I did new chain too) mock up, measure for spacers, make spacers, install, hit the road]
1. Difference between '99 down and '00 up rear wheels?
- People say '99 are a lot easier to work with, why exactly?
never heard that. here's the difference:
The axles are the same on both the 1999 & 2000. The difference is in the bearings and the raised rotor center. The 2000 rotors have a larger center hole. Because of the sealed bearings the 2000 wheels use a different length spacer. The 1999 and down wheels have bearings, seals and outside washer.
You can put a 1999 wheel on a 2000 model by using the earlier spacers and the 2000 rotor. However, in order to put a 1999 wheel on the 2000 model you would have to make the center hole on the rotor larger and use different spacers. You will also have to modify the rear pulley to fit on the later wheel."
Now that was referencing a Fat Boy, so not sure some of those things are universal, but it's a pretty legit explanation of the differences.
- I know '99 down has 3/4" axle, but are all '00 1" axles?
- I know '00 up have sealed bearings, I assume that's an advantage no?
I haven't had any issues with bearings and it's been 2 years (i think?) since the swap. I plan on replacing bearings when i replace sprocket in a few k miles. If you take your time and do it right, you won't have any issues at all.
- Does '00 up allow for a sprocket from Sprocket Specialties (or other place) to be bolted up?
not sure. I'd bet you could order a sprocket with that bolt pattern and our chain pitch, just as easy as I ordered mine.
best bet? call sprocket specialties and ask. If they can't do it, you're gonna be hard pressed to find another place that is somewhat affordable.
2. Wheels sizes
- What can I fit in the stock fender? Most people go with an 18" x 5.5". Can that fit with a 170/180 tire instead of a 200? Are there any 4.5" Harley rims that would work?
short answer, yes.
long answer, i wouldn't go lower than a 180 on a 5.5 rim. 200 looks tits, though. Do a little grinding on the subframe and the 200 fits no sweat. Or you could do what I did, and just put a steel fender on. You can do what you want as far as looks, and it's strong enough you can even let fat chicks ride your bike. You can find 'em cheap if you do some looking around and don't buy the first one you see.
3. Axle options
- Is there any downside to getting a 13.5" 3/4" harley axle for $20 instead of having my stock one turned down?
hell no. that's what I did, and it saved big$$
- If a '00 up wheel with 1" bearings worked, couldn't I just sleeve the stock axle to bring it to 1" in the middle?
axles arent different. see above. but, yes, if you got 1" axle wheels you could probably make it work. I would suggest seeing about getting bearings with OD of 1" and ID of whatever our axle is.
As far as i've ever seen, anyhow, most 1" axles are on the 23" front wheels and 8.5"+ rear wheels
Either way, there's so many 3/4 axle wheel choices out there, that this shouldn't even be an issue.
Other than that, it seems rather inexpensive to pick up a used caliper, CBR master cylinder, fabricate a brake stay, and figure out what spacers are need for the axle and sprocket.
--didn't install rear brake, but someone will chime in on that
--spacers are easy as shit. mock everything up, make sure your chain is straight, and measure for spacers.