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  #81  
Old 3 Weeks Ago
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Beelzeboss Beelzeboss is offline
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Sportster/Buell Model: XL1200S
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Quote:
Originally Posted by jkinkade
Good to see you getting the bike how you want it.

I put Buell peg's on mine as had a set. they are not as bulky as the stock sporty one's.
I like rear sets with reverse ( GP shift ). the roaring sporty racers in the 1990's up till about 1999. they all had rear sets reverse shift ( one up four down ); they used to ( some of them ) make there own shift leaver from a length of alloy, drill hole to fit shift spline tight. put another threaded hole for pinch bolt. you have to make a few bends, as it goes back over the derby clutch cover. then make a steel plate or alloy plate to bolt to rear of primary cover & mount foot peg too. narrows bike up and puts your feet higher. you have to pinch the shifter to the splined shift rod. Stortz made a spine cut set , but racers here in Australia I knew, did it this way as when they dropped there bikes, needed replacement sifters clutch & brake leavers, so kept a lot of spares & making shifter like that cheaper and worked.
Cheers mate, I'll keep that in mind if I can't source a stock lever this weekend. Cutting the internal splines was the only thing really stopping me from making my own lever.

Last time I rode the bike I noticed the petcock was leaking so I decided to pull it apart and improve my "manual conversion" which I'd done by flipping the spring in the vacuum section. The reason for converting to manual is so that there's one less thing to fail on the bike; a broken vacuum diaphragm can leave you stranded.



Basically I replaced the bits on the left with the aluminium plate on the right



Then, when reinstalling it I *think* I must have got a little dirt or swarf or something in the fuel line/petcock, because...



It seems that despite my best efforts the bike doesn't want to abandon traditional Harley activities like leaking everywhere haha

Time to pull the float bowl and check the needle and seat
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  #82  
Old 3 Weeks Ago
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Sportster/Buell Model: XL1200S
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I've also been working on making a new intake to give me some more knee room.

Inspired by the heavy breather I've put together a rough CAD model and render of what I think will work.



Obviously needs a little tweaking as I don't have the dimensions for the carb support/breather holes, so they're just guestimated at the moment.

If it works on my bike I'll make a few sets to sell. Current plan is all aluminium, the pipe will be TIG welded to the top flange, and at the base of the 3" pipe there's a venturi stepping down to the carb diameter so there's no abrupt transition.

Any 3" pod filter will work with the setup and I'll probably make a rain shield so you don't need to run a sock.
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  #83  
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jkinkade jkinkade is offline
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Sportster/Buell Model: XLH 88" 2003.
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Hi Mate , I have done that ( change to manual on off petcock ) just remember now every time you turn motor off you need to turn off petcock too. has your carb float bowl got a over flow hose from float bowl or none? no leaks from my old sporty.
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  #84  
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Sportster/Buell Model: XL1200S
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Quote:
Originally Posted by jkinkade View Post
Hi Mate , I have done that ( change to manual on off petcock ) just remember now every time you turn motor off you need to turn off petcock too. has your carb float bowl got a over flow hose from float bowl or none? no leaks from my old sporty.
Hey mate,
I've had it manual converted for about 3 months, just with the flipped spring mod, so I'm used to shutting it off when I stop (used to ride dirt bikes). The diaphragm eventually started leaking which made me do this aluminium plate mod.

My carb does have the overflow hose and that's where it's leaking from. I don't have the tools with me to pull the bowl off but early next week I'll get it torn apart and clean it out. Hopefully it's nothing serious... to go from no leaks at all to a flood I think means it probably has something stuck in the seat.
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  #85  
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Just messing around a bit with phone camera and Snapseed. Has some very cool effects.

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  #86  
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jkinkade jkinkade is offline
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It does look good!!

I have the over flow hose to float bowl too but am using a bobby wood cv that was a SE CV normally stock does not have that vent hose. but lucky u have it. as if dirt under the seat or float too high & manual petcock not turned off. only one way for that gas to go & that is into the motor. I once many years ago had my old Shovel Head Harley motor fill with gas like that. it was a kick start only!!
good luck
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  #87  
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Beelzeboss Beelzeboss is offline
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Join Date: Feb 2018
Location: Bathurst, Australia
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Sportster/Buell Model: XL1200S
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Quote:
Originally Posted by jkinkade View Post
It does look good!!

I have the over flow hose to float bowl too but am using a bobby wood cv that was a SE CV normally stock does not have that vent hose. but lucky u have it. as if dirt under the seat or float too high & manual petcock not turned off. only one way for that gas to go & that is into the motor. I once many years ago had my old Shovel Head Harley motor fill with gas like that. it was a kick start only!!
good luck
Ouch! Yeah I'm glad for the overflow hose haha. I cleaned out the carburetor and it's all sealed up again. There was quite a bit of gunk in the bowl which is a bit of a worry, but it's all gone now.

I also made a new intake at work, just as a proof of concept.

Radiused intake plate



All the components I manufactured



The little breather spacers and drilled bolts



And the finished product!



I wanted to make the pipe and top plate from aluminium so I could use 10mm plate and get a bigger radius on the inlet, but I wasn't able to source an aluminium mandrel bend before the weekend.

Let me know what you think!
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