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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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  #1  
Old 19th November 2021
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Default 04 Sportster refurb and build.

New to HD, but have had lots of bikes. Since I couldn't find a build forum here, I thought I would start mine.

The plan is to repair what is needed, and mod the rest. This includes a new clutch, new lower bars, new panniers and installing a vintage Vetter fairing to make a smaller tourer.

This is my story of HD exploration. Here is what I started with:







Started on the clutch today. Did not finish.









Turns out the clutch pack is jammed, will not compress at all. I'm going to have to cut the retaining clip, and try not to damage anything else. This I do tomorrow so I can take it to the dealer for parts. My guess is the spring plate in the middle of the pack is disintegrating. We shall see.

Interestingly the oil was clean and the magnet only has smooth fuzz on it.


With that I decided to remove the handlebars to start rewiring them. What a mess of splices.






That set aside for dinner and I will get back to it. Bike put up until tomorrow.



By the way, is this just a cover, or a SE carb?
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  #2  
Old 19th November 2021
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It’s a cover Jim, several styles available. While you’re doing the oil change do you still have the original plastic frame clamp with the plastic stud that holds the drain hose? I did have that stud fracture off on mine while in Florida a couple years ago. It’s hollow and I ended up pumping out the oil running across Ocala at night. Discovered a couple drops under the bike the next morning and found the cause. That clamp is a two year item, the MoCo changed it out to a solid plug starting with the 2006 models. Same part number I believe. There could be pictures in “Sportsterpedia “. About a $10.00 part but easy enough to change out while the bike is down and cheap insurance.
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  #3  
Old 19th November 2021
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Quote:
Originally Posted by sportsterpaul View Post
It’s a cover Jim, several styles available. While you’re doing the oil change do you still have the original plastic frame clamp with the plastic stud that holds the drain hose? I did have that stud fracture off on mine while in Florida a couple years ago. It’s hollow and I ended up pumping out the oil running across Ocala at night. Discovered a couple drops under the bike the next morning and found the cause. That clamp is a two year item, the MoCo changed it out to a solid plug starting with the 2006 models. Same part number I believe. There could be pictures in “Sportsterpedia “. About a $10.00 part but easy enough to change out while the bike is down and cheap insurance.
Thanks Paul. I do have the original clamp/drain plug, so good advice!
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Old 19th November 2021
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Nice thread. Subscribed. The wiring boogering is pretty disturbing
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Old 19th November 2021
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Thanks!

It was nearly impossible to get into first if the engine was running, and pulled even with the clutch maxed.

That said, I did manage to get it apart, but destroyed the pressure plate, retaining ring and clip.

Basically I had to force it to the point where the throwout bearing broke the retainer. Then I had to rig up a new press using the clutch tool and some scrap to get the retaining clip and ring out.


Here is the "spring clutch" in pieces:


You can see the brass rivets all over the place.




Some minor scoring, but I think it is fine to reuse the basket.


Sadly HD dealers here do not have the pressure plate in stock, said they could order it and will come in in a couple weeks. I told him I could get it online faster and cheaper.
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Old 19th November 2021
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They don’t call them grenade plates for nothing. The basket does clean up and is usable, many of us have gone through that issue. You have options if you choose to not replace the spring plate. 1. Adding two steels and one friction to make up the difference in stack size. 2. Use the replacement part that came out on the XR1200’s. 3. Purchase an extra plate replacement clutch through aftermarket.
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Old 19th November 2021
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Quote:
Originally Posted by sportsterpaul View Post
They don’t call them grenade plates for nothing. The basket does clean up and is usable, many of us have gone through that issue. You have options if you choose to not replace the spring plate. 1. Adding two steels and one friction to make up the difference in stack size. 2. Use the replacement part that came out on the XR1200’s. 3. Purchase an extra plate replacement clutch through aftermarket.
I purchased an extra plate kit with new diaphragm spring, no messing around. The old ones were pretty beat up, and a couple were even bent a bit.

The new pressure plate, retainer washer and clip were only $64, so I am not too upset about it.
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Old 19th November 2021
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Good for you, a healthy attitude like yours will get you far!
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Old 20th November 2021
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Now that I am waiting on clutch parts I turned to adding the fairing mount, and mid controls. The crash bar came in allowing me to set it up.








Not exactly the same as the excellent work by @c1skout but I decided to use some brackets I have. The brackets on the angle supports will be replaced by chrome ones to blend in a bit more.
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Old 20th November 2021
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Definitely the chrome looks better. Now to clean it up, flatten it and drill it, then all of it comes off to see if I can jam it in my powder coat oven.
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