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Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders Discuss Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders problems, advice, and/or how tos.

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  #51  
Old 9th October 2019
PetesPonies PetesPonies is offline
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I bought a used axle that is 3/4". I may have to add some metal and machine the head, to make it match the stock Sportster Axle. I will definitely be cutting and rethreading the other end. There is not a 3/4' axle that is the right length. So I will be cutting to correct length, turning down a new shoulder then turning down some more and threading the end. As for not wanting to thread . .?? It doesn't bother me a bit. I'll start the threads on the lathe and then do a clean up with a quality die.
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  #52  
Old 9th October 2019
farmall farmall is offline
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Most non-pros prefer to avoid threading. If you don't find it tedious than good for you!

BTW I get cheap/free lengths of round bar from my local machine shop and metal supplier who often have cutoffs left over from previous jobs/orders. Not just 1018 but sometimes 4140. It's worth getting to know them. Scrap steel prices are in the toilet recently so for bigger items scrapyards are worth a look. (Mine apologized for how little they gave for the last car I brought in!)

Glad ya got it done and happy machining!
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  #53  
Old 10th October 2019
PetesPonies PetesPonies is offline
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Well as a retired instructor, I used to even teach some machine shop. So I have threaded before, using a lathe. But with such fine threads, like I said, I'll finish it up with a die. But the lathe will get it started and concentric, without a lot of tearing. Don't want it stress points.
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  #54  
Old 8th July 2020
PetesPonies PetesPonies is offline
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Sportster/Buell Model: XLCH
Sportster/Buell Year: '59
Sportster/Buell Model #2: 2004 XL1200R
Other Motorcycle Model: 2006 XL1299R
Other Motorcycle Year: 2006
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My bike is running, but not happy with the braking. I bought an 11K mile R bike to build from . .but it wasn't really cared for. Point being, not sure the master cylinders are in good shape. I know the rear needs work or replacement. I got the front bled fine, to the dual Tokicos. But they don't feel as good as my other R with stock calipers. Any idea on option as far as an upgrade? Or maybe I just need a new R front master ?
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  #55  
Old 8th July 2020
farmall farmall is offline
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I've put braided stainless hoses on all my front brakes. I do it immediately when I get another bike. The braid limits brake hose expansion and reduces wasted lever travel.
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  #56  
Old 8th July 2020
PetesPonies PetesPonies is offline
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Sportster/Buell Model: XLCH
Sportster/Buell Year: '59
Sportster/Buell Model #2: 2004 XL1200R
Other Motorcycle Model: 2006 XL1299R
Other Motorcycle Year: 2006
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I do understand that. I'm dealing with a situation that is much different than just a hose change though. I may need to rebuild the stock MC or get a new one . .was why I was asking about any upgrades that are known?
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  #57  
Old 8th July 2020
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Redbeard2 Redbeard2 is offline
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Sportster/Buell Model: M2 Cyclone
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Default XL front Brake Upgrade

PetesPonies said, "There appears some misinformation here."

I was unaware that the first H-D Sportster 48's had 39mm forks at the time of my post. Pete is correct that the cheapest way to go on his front axle engineering changes is to buy a used axle and turn it down to .750" if it is not hollow. The 1.000" 49mm fork midglide axles were solid. I've upgraded my Sportster and Dyna with 49mm midglide front ends and used the newer 25mm axles. Both of them were hollow and turning down to .750" is not advised if it is even feasible.
Pete, your Sporty looks great! Can you post a bigger picture of your front brakes? Also what brand of calipers are you using?
Did your Sporty come with single or dual front brakes originally? If you're not running the 11/16" master cylinder [the type used on Road Kings and Electra Glides] then you need to get one. Either a new one or a used one from Ebay will work fine.
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  #58  
Old 9th July 2020
PetesPonies PetesPonies is offline
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Sportster/Buell Model: XLCH
Sportster/Buell Year: '59
Sportster/Buell Model #2: 2004 XL1200R
Other Motorcycle Model: 2006 XL1299R
Other Motorcycle Year: 2006
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I have two Rs . or Roadsters. So I have a good way to compare stock to modified. I modified my other R as well, with different wheels and still kept the dual front brakes. But the brake components are all stock. It brakes much better than any Harley I had ever owned. But I decided to build a Hot Rod Sporty. So I bought another R and here we are today I used a 3/4 axle from a BT. Thus, I had to shorten it and turn some down areas to work with the lowers, then re-thread the end,etc. But it was definitely the way to go. The calipers are Tokicos from a Suzuki Rocket. Don't my Roadsters have the 11/16" MC stock?





The Blue R is is my other bike. Stock brakes, modified wheels.

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  #59  
Old 9th July 2020
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Sportster/Buell Model: M2 Cyclone
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Sportster/Buell Year #2: 2006
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Other Motorcycle Year: 2002
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Default Sportster Front Fork Upgrades

After seeing your 48 front wheel which sports a 130-16 tire I now understand why your stock axle wasn't long enough. You need a mid glide or wide glide to run one of these and the 7" narrow glide axle isn't long enough! But I digress! As far as I know the Roadsters all ran dual disk brakes stock and therefore should have been equipped with an 11/16" master cylinder. If you need a larger master cylinder here is the last word: https://www.ebay.com/itm/Brembo-Raci...53.m1438.l2649
It's a 19mm Brembo radial master cylinder. 19mm=.748" ID. An 11/16" H-D master cylinder is .6875 ID. The only problem with this Brembo on a Harley is that you'll have to run a hydraulic brake sensor as the stock Harley brake light switch will not work on it. This set up will make your Sportie do a stoppie every time if you are so inclined!
Here's the link to my Sportie front end upgrade: http://xlforum.net/forums/showthread.php?t=1609609
In addition to my front end upgrade I upgraded the motor with a 1250 S&S sidewinder kit [it was originally an XL883], Screamin' Eagle heads, Mikuni HRS42 carb with Arlen Ness Big Sucker and H-D low restriction air filter, Screamin' Eagle 536 cam set, Pingle petcock and a Vance & Hines 2 into 1 exhaust system. I upgraded the rear suspension with Ohlins HD144 shocks.
I forgot to mention that my Sporty upgrade used the later model H-D 300mm [11.8"] rotors. The older rotors are 292mm [11.5" dia.]. Here's my latest front end build which is on my 05 Dyna. Up until 05 Dynas had the same front end as a Sportster. In 06 they went to the 49mm forks with an 8.5" midglide triple trees. On my Dyna front end project in addition to using the XR1200 front wheel [like on my Sportster] I upgraded the brakes with 320mm Brake Tech Rotors [same size as on most crotch rockets]. Here's the link: https://www.v-twinforum.com/threads/...pgrade.544405/
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  #60  
Old 9th July 2020
PetesPonies PetesPonies is offline
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Other Motorcycle Year: 2006
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It's not a 48 front wheel. 48s don't have a mounting area for the second rotor. I built this wheel to have a 16 x 3 laced wheel, but with a hub that would mount two rotors. People seem to look over this, don't understand how difficult this was. Find a dual hub, but one that will work with a mid glide tree and mate to the Roadster lowers I don'rt build this stuff all the time . . . . but I found no one who had done it. So I figured it out as I went. But it looks factory, part of what I like to do. Make someone scratch their head . . like they think they know what they're looking at, until something doesn't add up. Then it . WTF is going on here I will definitely look at that MC. I was trying to have a bike that stops like a Ricer It's just one up, just to have fun. Problem is, my wife loves the look of it, better than the Blue one I made her watch "Harley Davidson and the Marlboro Man", so she could see how she would have to ride it, if she was so inclined LOL Thanks!!!! Also, the MC from the Suzuki which this calipers are from uses I believe a 19mm bore. So I know I'm down on size and expected more travel . . but for whatever reason, it just isn't getting it done. So, you are using a 15mm ( 11/16 ) and it seems to feel and stop good? If so, it just may be my hunch that my MC needs to be rebuilt or replaced. Do you know what MCs the VRod and Buell, even the XR1200 used? Are none larger than 15MM from Harley ?
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