The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Styles > Cafe Racer Sportster Motorcycle Talk
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Notices

Cafe Racer Sportster Motorcycle Talk Sleek, fast and cool. Discuss your Cafe Racer Sportster Motorcycle

Active Threads
0 Fork oil q
Last Post: Pickss
Posted On: 5 Minutes Ago
Replies: 4
Views: 224
0 New oil tank
Last Post: npaisnel
Posted On: 13 Minutes Ago
Replies: 115
Views: 5,614
0 Swing arm pivot
Last Post: Mike1nw
Posted On: 33 Minutes Ago
Replies: 0
Views: 5
0 What did you do for your sporty Today?
Last Post: Nibelungen
Posted On: 34 Minutes Ago
Replies: 7,195
Views: 1,058,139
0 Not a Sporty Carb..but CV
Last Post: npaisnel
Posted On: 47 Minutes Ago
Replies: 4
Views: 375
5 1200 or 883
Last Post: boomerguy
Posted On: 48 Minutes Ago
Replies: 1,229
Views: 365,512
0 Hottie of the day, no nudity.
Last Post: Stairman
Posted On: 49 Minutes Ago
Replies: 23,290
Views: 2,375,372
0 excellent color
Last Post: Stairman
Posted On: 53 Minutes Ago
Replies: 11
Views: 546
0 Do not buy this oil!
Last Post: 60Gunner
Posted On: 1 Hour Ago
Replies: 48
Views: 1,796
0 1986 Adjustable Push Rod Adjustment
Last Post: 109Countries
Posted On: 1 Hour Ago
Replies: 15
Views: 305
0 stress killer
Last Post: Nibelungen
Posted On: 1 Hour Ago
Replies: 414
Views: 82,114
0 New Harley CEO
Last Post: Steve9
Posted On: 1 Hour Ago
Replies: 7
Views: 343
0 XLH 900 1969 Build Thread
Last Post: K2019
Posted On: 2 Hours Ago
Replies: 14
Views: 293
0 IH Crankcase Pressure and Engine Breathing
Last Post: Hippysmack
Posted On: 2 Hours Ago
Replies: 85
Views: 4,164
0 Early Sportster XLCH 900 Dyno Run
Last Post: Ferrous Head
Posted On: 2 Hours Ago
Replies: 109
Views: 32,564
0 top end rebuild
Last Post: Ferrous Head
Posted On: 2 Hours Ago
Replies: 79
Views: 4,339
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Graywolf
Posted On: 3 Hours Ago
Replies: 48,657
Views: 7,872,466
0 Hi everyone
Last Post: jharback
Posted On: 3 Hours Ago
Replies: 18
Views: 629
0 New member
Last Post: jharback
Posted On: 3 Hours Ago
Replies: 11
Views: 321
0 newbie
Last Post: jharback
Posted On: 3 Hours Ago
Replies: 14
Views: 212
6 Hello Folks
Last Post: jharback
Posted On: 3 Hours Ago
Replies: 10
Views: 197
14 Buell back in business?
Last Post: Steve9
Posted On: 3 Hours Ago
Replies: 6
Views: 309
0 Tired of hearing the Sportster is a girls bike (The one and only Girly Bike Thread)
Last Post: Steve9
Posted On: 3 Hours Ago
Replies: 4,142
Views: 805,369
0 Iree's late night cafe
Last Post: ~Grind~
Posted On: 3 Hours Ago
Replies: 1,739
Views: 239,914
0 Ironhead Exhaust Poll
Last Post: sportsterdoc
Posted On: 5 Hours Ago
Replies: 193
Views: 55,911
0 random rattle
Last Post: rejeanprimeau
Posted On: 7 Hours Ago
Replies: 13
Views: 592
0 WTS: Forward Controls 2004-13
Last Post: 60Gunner
Posted On: 16 Hours Ago
Replies: 8
Views: 353
0 Latest trip to dealer + comments...
Last Post: sportsterdoc
Posted On: 16 Hours Ago
Replies: 17
Views: 989
0 Vulcan Mid Glide Triple Tree Conversion Set
Last Post: Dariusz
Posted On: 17 Hours Ago
Replies: 0
Views: 60
0 Do you use premium gas in your Sportster?
Last Post: Marsikus
Posted On: 17 Hours Ago
Replies: 1,839
Views: 394,393
More...
Members Birthdays
patc, Camera108 (67), pbudrovic (65), Rob Roy's Revenge (64), gene04 (63), guvnor (56), jrogers329 (50), ksoggs (45), dmurphy68 (43)
Reply
 
Share Thread Tools Display Modes
  #1  
Old 29th August 2015
chris_b_owens's Avatar
chris_b_owens chris_b_owens is offline
Harley Engineer
 
Join Date: Jun 2014
Location: Mountain House, CA
Posts: 317
Sportster/Buell Model: Sportster Iron 883
Sportster/Buell Year: 2013
Reputation: 114922
chris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud of
Default DIY Belt Tensioner for taller shocks and Cafe Bikes

So I wanted to install some taller shocks than the 13" Burly Stilettos that I had. I decided to go with the 15" version and I am very happy with them. I did have an issue with a very loose belt and because of the new geometry the belt was just barely rubbing on the exhaust bracket.

I decided I would definitely need a belt tensioner and started looking for one. Unfortunately I didn't find much. Free Spirits makes a top quality one but it is expensive and uses the same mounts as my RSD exhaust.

I then figured I would try and make something work so here is what I came up with.

I found this Dorman 419-109 belt tensioner for cars on Amazon for $20. The reviews looked good so I figured I would pull the trigger.
http://www.amazon.com/gp/product/B00...ilpage_o02_s00

When I got it I was pretty happy. It seems to be solidly built and has a very sturdy spring. The only downfall is that the idler pulley is plastic but I guess it doesn't need to be all that strong.



I went to the local hardware store and bought some 1.5 12guage angle iron. I cut off about a 4 inch piece of it.



I laid the tensioner on it and marked where the holes would be. I punched the center and drilled them out to fit some 3/8 socket head bolts. I grinded the corners and smoothed everything out with a sanding flap disk on my angle grinder.





Next I found a place on the RSD exhaust mounting bracket where I could mount it. I marked the holes and drilled on the bracket the same way I did on the angle iron.



I had to trim up the angle iron on the exhaust bracket side to shorten it up.



Mounted it to the newly drilled exhaust bracket.



I test fitted everything and it all lined up pretty well.





Painted the bracket up with some satin black rattle can. Mounted it all back up using some red Loctite on the threads.





Mounted up the exhaust and we are done!





Here is the before:



And the After:



It all seems to work really well. The tensioner is spring loaded and all seems to be good for now. I will keep you posted.

Now I know it would be better and arguably easier to have welded a piece of flat bar to the exhaust bracket and accomplish the same thing. Unfortunately I do not have any welding equipment as of yet but when I do I will having a lot of fun making all kinds of stuff.

Hope this helps some of you that have ran into the same problem.
Reply With Quote
  #2  
Old 29th August 2015
sportsterdoc's Avatar
sportsterdoc sportsterdoc is offline
Senior Master Custom Bike Builder
 
Join Date: Apr 2012
Location: Mojave Desert
Posts: 13,742
Sportster/Buell Model: 1200S
Sportster/Buell Year: 2002
Sportster/Buell Model #2: XLH883
Sportster/Buell Year #2: 2003
Reputation: 6722851
sportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond reputesportsterdoc has a reputation beyond repute
Default

Nicely done
Be interesting to track the belt life
What is the seat height?
Two of your pics show a ground strap. Is that frame to motor?
Reply With Quote
  #3  
Old 29th August 2015
chris_b_owens's Avatar
chris_b_owens chris_b_owens is offline
Harley Engineer
 
Join Date: Jun 2014
Location: Mountain House, CA
Posts: 317
Sportster/Buell Model: Sportster Iron 883
Sportster/Buell Year: 2013
Reputation: 114922
chris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud of
Default

Quote:
Originally Posted by sportsterdoc View Post
Nicely done
Be interesting to track the belt life
What is the seat height?
Two of your pics show a ground strap. Is that frame to motor?
Thank you! It is the ground on the rear stabilizer linkage. The seat height is right at 32"
Reply With Quote
  #4  
Old 29th August 2015
madlim madlim is offline
Flat Track Champion
 
Join Date: May 2011
Location: Sweden
Posts: 649
Sportster/Buell Model: XL1200N
Sportster/Buell Year: 2008
Reputation: 555668
madlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond repute
Default

Thank you for sharing this Chris, I've been fiddling with something like this in my mind for quite some time.
Reply With Quote
  #5  
Old 29th August 2015
Bone's Avatar
Bone Bone is offline
Senior Master Custom Bike Builder
 
Join Date: Jun 2009
Location: Medford, NJ
Posts: 11,043
Sportster/Buell Model: FLHP
Sportster/Buell Year: 2016
Sportster/Buell Model #2: Guzzi V7 Stone
Sportster/Buell Year #2: 2013
Other Motorcycle Model: 18 Guzzi V7D / 11 Duc 696
Reputation: 4388060
Bone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond reputeBone has a reputation beyond repute
Default

Thanks for that. Good luck with it, but it looks like you're on the right track!
Reply With Quote
  #6  
Old 30th August 2015
Ranchero50's Avatar
Ranchero50 Ranchero50 is offline
Senior Chief Master Mechanic 2nd Class
 
Join Date: Aug 2014
Location: Hagerstown MD
Posts: 1,571
Sportster/Buell Model: 1200 Street Brawler
Sportster/Buell Year: 2005
Reputation: 932639
Ranchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond reputeRanchero50 has a reputation beyond repute
Default

Looks good, might have to copy it. See, this is the kind of customizing stuff we wrote about before.

One nice thing is down the road you should be able to swap out the pulley for something sexier.
__________________
The build thread... http://xlforum.net/forums/showthread.php?t=1821880
Reply With Quote
  #7  
Old 30th August 2015
madlim madlim is offline
Flat Track Champion
 
Join Date: May 2011
Location: Sweden
Posts: 649
Sportster/Buell Model: XL1200N
Sportster/Buell Year: 2008
Reputation: 555668
madlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond reputemadlim has a reputation beyond repute
Default

Bah, couldn't help myself, just ordered the same belt tensioner....
Reply With Quote
  #8  
Old 30th August 2015
chris_b_owens's Avatar
chris_b_owens chris_b_owens is offline
Harley Engineer
 
Join Date: Jun 2014
Location: Mountain House, CA
Posts: 317
Sportster/Buell Model: Sportster Iron 883
Sportster/Buell Year: 2013
Reputation: 114922
chris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud of
Default

Quote:
Originally Posted by Ranchero50 View Post
Looks good, might have to copy it. See, this is the kind of customizing stuff we wrote about before.

One nice thing is down the road you should be able to swap out the pulley for something sexier.
Lol Go for it! That's why I posted it.


Quote:
Originally Posted by madlim View Post
Bah, couldn't help myself, just ordered the same belt tensioner....
Lol nice!
Reply With Quote
  #9  
Old 30th August 2015
XLXR's Avatar
XLXR XLXR is offline
XL FORUM LIFE MEMBER
 
Join Date: Aug 2006
Posts: 12,201
Sportster/Buell Model: XL1200 R
Sportster/Buell Year: 2006
Reputation: 711676
XLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond reputeXLXR has a reputation beyond repute
Default

Looks good, but be careful on first few test rides. On rubbermounts, shocks that long with short forks puts the bike on the edge of the high speed wobble zone.
__________________
Former Ricor test rider for IAS Shocks, Intiminators and Vibranators. Works Dual Rate fork springs, fork brace, Avon Venom X tires, loosen drive belt, and set frame rails level to floor. Read the "7 Pages of Suspension" thread in the Suspension Sticky Index to learn how to fix your suspension.
Reply With Quote
  #10  
Old 30th August 2015
chris_b_owens's Avatar
chris_b_owens chris_b_owens is offline
Harley Engineer
 
Join Date: Jun 2014
Location: Mountain House, CA
Posts: 317
Sportster/Buell Model: Sportster Iron 883
Sportster/Buell Year: 2013
Reputation: 114922
chris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud ofchris_b_owens has much to be proud of
Default

Quote:
Originally Posted by XLXR View Post
Looks good, but be careful on first few test rides. On rubbermounts, shocks that long with short forks puts the bike on the edge of the high speed wobble zone.
I got it up to 118 or so right after install with no issues but just in case I went ahead and installed a steering stabilizer to be safe. Works like a charm and rides great.
Reply With Quote
Reply

Bookmarks


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump



All times are GMT +1. The time now is 18:19.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2020, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC