A Reliable Engine

[ZCarFan]

Originally Posted by John Harper

Since they made ~40,000 Sportsters in 2020, the elimination of the trapdoor saved them $200,000? That seems suspect. For a huge company, that's barely the price of one engineer, or VP.

http://investor.harley-davidson.com/...irol-shipments

That number also seems to include the Street models too. So, even less of a savings most likely.

John

Have to include all XLs from 2004 to present.

There will also be a number of other small cost-cutting actions taken that in aggregate make a sizeable difference to the bottom line. The benefits mostly go uphill in the organization and the lower you go (all the way down to the consumer) the less the benefit, sometimes actually a negative return. For example, eliminating the trapdoor might be one of hundreds of cost-cutting measures that end up as bonuses to management, but cost you a bunch more if the transmission has to be repaired. This is a good example as well since the majority of buyers won't ever need to take the transmission apart and the few that do will likely do so long after the purchase. Any negative feedback such as swearing off the brand in favor of competitors is so far removed from the purchase that it never has an effect on marketing, planning, engineering, etc.

[John Harper]

It's obviously more than a $5 decision. The entire case had to be redesigned, as well the frame, and didn't they also change the cut of the gears at one point? Perhaps the door itself cost the company $5, but much more was involved than just the door.

John

[ZCarFan]

Originally Posted by John Harper

It's obviously more than a $5 decision. The entire case had to be redesigned, as well the frame, and didn't they also change the cut of the gears at one point? Perhaps the door itself cost the company $5, but much more was involved than just the door.

John

They were already redesigning the frame and cases for the rubber engine mounts.

Anyway, it doesn't matter how much or how little money was invested to make the change, if they projected a net savings of $5 per unit, that's the number.

[rejeanprimeau]

Crank failure on newer H-D. Two reason: lugging and engine braking. Don't lug it and downshifting only moderately. Fifth speed at 30 mph and the crank go wide and downshifting the crank go narrow. Without compensating sprocket that what happen. IMO

The moco just add a better nut on the crank thinking it will solve the problem.

Keep the engine at 3750 rpm and no problem. Learn to shift and moderates downshifting and those 2004/2005 will be good.

[Steve9]

Reajean,

You probably right.

I don't lug anything, but I downshift my '81 and '03 pretty aggressively I would hate to have to "baby" these bikes.
And I fixed the back brake on my '03....

moco should have addressed this earlier. It's like ZCarFan said above; probably last until the bike is a bit older so the moco takes a smaller hit.

Public company never wants to have a bad qrtr, lets them do the wrong thing

Just my opinion

[wedge]

I have put cranks in two 04's. I have two 05's and no sign of crank failure on either so far. (I'm not kind to either bike. I keep my rev limit at 7,000 and like to get it up there regularly).

On the two I did, it was the front rod bearing that went. The rear on both was still solid. A Buell crank is a good replacement if you can still locate one. I used Buell cranks in both, and I have a spare Buell crank for the inevitable fail of one of mine.

When they went out, both 04's seized the inner cam bushings from the crank debris, that locks them up and the pinion then spins on the crank to save the rest of the engine.

I got involved in the second one after a local mechanic tried putting a second set of new pistons on the bad crank without noticing that the cams were froze and the pinion spun. "Mechanic"?

To determine if the crank is bad with the crank out just hold the front rod in your fist like choking a chicken and then use your other closed fist to hammer on top of the fist holding the rod. You will hear the knock very loudly even if it's slight. With crank still in the cases you do the same by using first fist to pull up on rod as you hammer the top with the other fist, it will show in the same way.

I know a machinist here in California that rebuilds the stock cranks but I like the Buell crank so I have not had him rebuild one yet. He is the best when it comes to cam bushings though.

Dark Horse will build you a great crank, but it will be pricey. If you go that route, its' best to send them the cases and let them do the crank as well as new case bearings at the same time.

[rocketnorton]

like the knock test
never heard of it b4

[Crusty]

If the rod moves around like a joystick and also makes a loud knock when you hit your hand holding it, that's another indication, I think.

[Turbo Sporty 48]

Ordered a XR crank from New Castle, they sent the crank to Darkhorse for a crank pin weld and a true check.
No complaints here.