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Sport-Glide / Sportster Motorcycle Touring This section is for the discussion of setting up you Sportster motorcycle touring and long distance riding.

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  #11  
Old 3 Weeks Ago
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Gunwish - I saw that you replaced the clutch cable. Did you inspect the clutch pack (specifically the spring plate). The spring plate is a common failure in rubber mounts and mine grenaded at 26K. If it was me I would replace it with an extra plate kit, but I would advise to at least check it to make sure the rivets are in good shape. It can cause damage when it comes apart.

The other issue is the starter and ignition relays (little black boxes in fuse box), they get corroded and they fail. I have had my bike 10 years and logged 65K and have replaced them 3 times and always carry two spares when I travel any distance. I also pull all my fuses and relays and clean the contacts and fuse box every year or before a long trip.

Another fault I have heard of (but not experienced) is the crank position sensor. I have also heard that it is only a problem in certain years (but I don't know any more than that). Might want to look into that and maybe carry a spare.

Another bit of advice is make sure all bolts are tight to spec. I lost both of my front upper engine isolater (dog bones) mount bolts on a trip once. When I replaced them I used blue locktight and haven't had an issue since (but always check them).

Last bit of advice is the drive belt adjustment. I have always kept mine looser than factory specs (and I am still running the original belt). I have heard others here voice the same advice.

Not to make you paranoid, my Sporty has never stranded me on a trip, but preparedness is good insurance. have fun, stay safe and enjoy your trip.
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  #12  
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kkbii kkbii is offline
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Thats a great idea Paul. I will do just that when i replace my belt this weekend.
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  #13  
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A quick note on the "Engine air" pump, it doesn't fill your tire with gas vapor, draws fresh air from around you. I pack one as well as the "Stop-Go", plug kit. They are lubricated mushroom head plugs and do an incredible job! Won't help on tubed tires.

Kelley, that bolt really doesn't do much and won't be missed.
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  #14  
Old 3 Weeks Ago
Crusty Crusty is online now
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Quote:
Originally Posted by sportsterpaul View Post
Kelley, that bolt really doesn't do much and won't be missed.
How many Sportsters does Harley make per year? Don't you think that the bean counters would have an orgasm at the thought of saving the cost of 50,000 bolts? If it wasn't that important, the factory would leave it off. Do what you want; it's your bike, but I'd rather have to remove the exhaust than have the sprocket cover crack and break and maybe get jammed between the belt and sprocket.
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