The Sportster and Buell Motorcycle Forum - The XLFORUM®
 

Go Back   The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Era Specific and Model Specific > Frame Mount EVO Sportster Talk (1986-2003 models)
XLF Blogs XLF Arcade XLF Disclaimer/Privacy Statement/Terms Of Use

Notices

Active Threads
0 Keep & Kill
Last Post: XL Ed
Posted On: 5 Minutes Ago
Replies: 30,840
Views: 1,806,195
0 Stupid Mikuni question
Last Post: darwin-t
Posted On: 29 Minutes Ago
Replies: 2
Views: 47
0 Occasional pinging
Last Post: doodah man
Posted On: 1 Hour Ago
Replies: 1
Views: 38
0 Ironhead and Owner - Post Yer Pics If You dare!
Last Post: JonesL
Posted On: 1 Hour Ago
Replies: 216
Views: 65,516
0 Sportster Oil Pressure and Dynamics
Last Post: Hippysmack
Posted On: 1 Hour Ago
Replies: 446
Views: 35,666
0 bent the L/side foot peg mount
Last Post: 1Scooter
Posted On: 1 Hour Ago
Replies: 1
Views: 60
0 Looking for vin# 69xlch9664
Last Post: IronHeadRon
Posted On: 2 Hours Ago
Replies: 1
Views: 163
0 New Brake Light Wiring Issues
Last Post: IronHeadRon
Posted On: 2 Hours Ago
Replies: 5
Views: 183
0 a different kind of set back
Last Post: IronHeadRon
Posted On: 2 Hours Ago
Replies: 4
Views: 172
0 2 capacitor questions
Last Post: IronHeadRon
Posted On: 3 Hours Ago
Replies: 18
Views: 464
0 Brake fluid
Last Post: brucstoudt
Posted On: 4 Hours Ago
Replies: 5
Views: 159
0 Had my 73 tank striped
Last Post: Toejam503
Posted On: 5 Hours Ago
Replies: 4
Views: 189
0 Happy Birthday Xena!!!
Last Post: Toejam503
Posted On: 5 Hours Ago
Replies: 6
Views: 129
0 Hottie of the day, no nudity.
Last Post: Stairman
Posted On: 6 Hours Ago
Replies: 38,802
Views: 4,981,493
0 Iree's late night cafe
Last Post: Stairman
Posted On: 6 Hours Ago
Replies: 2,354
Views: 464,420
0 Pushrods Won't Hold Adjustment
Last Post: Chuckthebeatertruck
Posted On: 7 Hours Ago
Replies: 32
Views: 2,162
0 Aluminum polishers
Last Post: mikethebike61
Posted On: 7 Hours Ago
Replies: 32
Views: 4,045
0 Another transformation coming
Last Post: sportsterpaul
Posted On: 8 Hours Ago
Replies: 2
Views: 79
0 Trying to balance a wheel
Last Post: sportsterpaul
Posted On: 8 Hours Ago
Replies: 5
Views: 187
0 winding idle up excessively to start bike.
Last Post: 73HEAD
Posted On: 10 Hours Ago
Replies: 66
Views: 3,831
0 Food porn
Last Post: Stairman
Posted On: 11 Hours Ago
Replies: 2,879
Views: 755,331
6 Secret photo"s of folkies loft
Last Post: Stairman
Posted On: 11 Hours Ago
Replies: 1,622
Views: 295,905
0 XR-750 oil tank
Last Post: mofosheee
Posted On: 14 Hours Ago
Replies: 0
Views: 48
0 Official XL Forum Random Image Thread (NO NUDITY!)
Last Post: Stairman
Posted On: 15 Hours Ago
Replies: 55,230
Views: 9,443,610
0 Birthday wishes to our resident Asgardian!
Last Post: cal43
Posted On: 16 Hours Ago
Replies: 13
Views: 231
0 video & pics
Last Post: cal43
Posted On: 16 Hours Ago
Replies: 1,776
Views: 180,563
0 Rebuilding and Tuning a S&S GBL carburetor
Last Post: thefrenchowl
Posted On: 17 Hours Ago
Replies: 91
Views: 3,735
0 This is gonna hurt.
Last Post: cal43
Posted On: 17 Hours Ago
Replies: 9,813
Views: 2,399,328
0 Hot Chicks on Hot Bikes
Last Post: cal43
Posted On: 17 Hours Ago
Replies: 13,362
Views: 3,453,076
More...
Members Birthdays
BobH (68), jcrow (68), release (67), Iron Joker (62), mickes (58), indyrednek (58), jarhead08, koidac (46)
Reply
 
Share Thread Tools Display Modes
  #41  
Old 6th June 2021
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

Thanks for taking the time to make up those diagrams. I'm in agreement with you that side guide lines would have been a asset. Regarding the diagrams of the bolts not being able make contact with the top of the hole, this situation, had it existed, would have resulted in the fender sitting HIGHER than if the bolts made full contact with the top of the mount holes. My question here is trying to figure out why the fender LOWERED so much. And its not a problem, I like the new fender position. I'm just trying to satisfy my curiosity.

"Besides, the OEM hole is bigger than the bolt.
Means there is a fudge factor in OEM install where the bolts could have been in the bottom of the holes.
Loosen and push down may have revealed a built in 3 mil fudge factor.
Then you widened that."

No, that wasn't the case. Still mystified.
Prior to grinding the fender was fully pushed DOWN onto loosened mounting bolts, if pushed UP in the slightly oversized factory mounting holes the top of the fender made contact with the bottom of the fork brace well before the slop in the mounting holes was taken up. When pushed down and all 4 bolts were firmly in contact with the top of the fender mounting holes (if you read the full post you will see I had the entire front end removed from the bike and was re-installing it piece by piece.) and confirmed visually, and it yielded approximately .006" fender to fork mount clearance.
After grinding the mounting holes the now elongated mounting holes measured from bottom to top EXACTLY 3 mm longer in the now enlarged vertical dimension than the original factory mounting holes.
Once again the fender was fully pushed DOWN onto loosened mounting bolts and all 4 bolts were firmly in contact with the top of the now lengthened fender mounting holes and this was also confirmed visually. This yielded just over 6 mm of fender to fork mount clearance.
OK, I'm moving on from this subject now, we have beaten it to a well deserved death!
The new clearance is fine and I'm leaving town for work.
Reply With Quote
  #42  
Old 6th June 2021
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

Thanks for taking the time to make up those diagrams. I'm in agreement with you that side guide lines would have been a asset. Regarding the diagrams of the bolts not being able make contact with the top of the hole, this situation, had it existed, would have resulted in the fender sitting HIGHER than if the bolts made full contact with the top of the mount holes. My question here is trying to figure out why the fender LOWERED so much. And its not a problem, I like the new fender position. I'm just trying to satisfy my curiosity.

"Besides, the OEM hole is bigger than the bolt.
Means there is a fudge factor in OEM install where the bolts could have been in the bottom of the holes.
Loosen and push down may have revealed a built in 3 mil fudge factor.
Then you widened that."

No, that wasn't the case. Still mystified.
Prior to grinding the fender was fully pushed DOWN onto loosened mounting bolts, if pushed UP in the slightly oversized factory mounting holes the top of the fender made contact with the bottom of the fork brace well before the slop in the mounting holes was taken up.
When pushed DOWN and with all 4 bolts firmly in contact with the top of the fender mounting holes and confirmed visually, it yielded approximately .006" fender to fork mount clearance.
After grinding the mounting holes the now elongated mounting holes measured from bottom to top EXACTLY 3 mm longer in the now enlarged vertical dimension than the original factory mounting holes.
Once again the fender was fully pushed DOWN onto loosened mounting bolts and all 4 bolts were firmly in contact with the top of the now lengthened fender mounting holes and this was also confirmed visually. This yielded just over 6 mm of fender to fork mount clearance.
OK, I'm moving on from this subject now, we have beaten it to a well deserved death!
The new clearance is fine and I'm leaving town for work.
Reply With Quote
  #43  
Old 6th June 2021
Hippysmack's Avatar
Hippysmack Hippysmack is offline
XL FORUM TEAM MEMBER
 
Join Date: Jul 2014
Posts: 8,860
Sportster/Buell Model: Xl1250S
Sportster/Buell Year: 98
Other Motorcycle Model: Kawasaki Vulcan 500
Other Motorcycle Year: 95
Reputation: 8995933
Hippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond reputeHippysmack has a reputation beyond repute
Default

Of course, I don't know for sure what happened.
You would have to compensate up top for the holes not being completely vertical was my thinking.
A thought was maybe the compensation thru off the cut measurements.
But all in all, you could measure from the lip under the fender down to the holes and scribe from there as a different way to get there.
Anyway......
__________________
Diagnosis begins before teardown, during and after rebuild.

In Search of Fuel, Sunshine and a Steady Idle.

Reference the XLFORUM'S Sportsterpedia
for additional technical information & advice
Reply With Quote
  #44  
Old 6th June 2021
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

ya know, hindsight is a wonderful thing..... if I could do this over I'd have Randy make a little template from some harder material like stainless that those bits wouldn't cut and clamp it to the fender mount and let that guide the grind....oh well, too late
Reply With Quote
  #45  
Old 22nd May 2022
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

Due to many factors almost a year has gone by since I have done anything with the Sportster. Wanting to touch up the small damage that I had inflicted on the front fender mounting bracket, I called Color Rite and asked what I should have on hand for fixing the fender and any future minor accidents to my paint.
Thought I'd better buy some before my factory color "Jade Sunglow" was dropped due to age. This is what they sent me:

Tack Cloth
Surface Cleaning Prep Wipes
4 different grades of abrasive paper
Primer
Clearcoat
Light Cut Polishing Compound
Colorcoat #1168 Base
Colorcoat Jade Sunglow









Reply With Quote
  #46  
Old 22nd May 2022
rejeanprimeau's Avatar
rejeanprimeau rejeanprimeau is offline
XL FORUM TEAM MEMBER
 
Join Date: Jun 2011
Location: On a farm
Posts: 7,006
Sportster/Buell Model: XL77.2R
Sportster/Buell Year: 2006
Reputation: 4986309
rejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond reputerejeanprimeau has a reputation beyond repute
Default

My favorite touch out paints: nail polish or model plane paint. With the young painting their finger nails the choice of color is almost without limit. 2$ and it's not like it's in full view like a gas tank.
Reply With Quote
  #47  
Old 28th May 2022
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

imgbb stopped working for me
I reviewed the sticky(s) here just to be sure I wasn't making a mistake and tried several more times with the same result.
doesn't seem to be any point in posting without pics
don't know why this website isn't set up to allow pics to be uploaded directly from a users computer
Reply With Quote
  #48  
Old 3 Weeks Ago
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

The oil lines looked OK but just in case I made up a full set of oil lines to replace the original 2002 rubber.
I used Gates oil cooler hose with stainless fuel injector clamps on the 1/4" and 3/8" hose and Comp Cams stainless hose clamps on the 1/2" hose. I just couldn't bring myself to use Home Depot garden center hose clamps... I have acess to a HD factory style Oetiker Crimp/Clamp kit from a friend but decided against it as I know I'm gonna be cracking these lines when I prime and pre lube the engine. Those crimped Oetiker clamps sure do look nice though.
I considered replacing the 2 HD factory polymer fittings (Tee and Elbow) with brass but decided to keep the stock synthetic parts.
Hoses and clamps (excluding the high pressure hose) came to a hair under $200. I would have expected this if I was buying actual HD factory parts (these items are obsolete on HD microfiche) but it was a shock to see this pricing from auto parts stores. Thank you to our current administration......

The pump to filter hose is from American IronHorse Buell parts and the 2007 hi scavenge oil pump is from Hammer Performance.

Next up is to replace the various vent and vacuum hoses which are showing age cracks at the ends over the fittings.

Reply With Quote
  #49  
Old 3 Weeks Ago
Cyclone14 Cyclone14 is offline
Greasemonkey
 
Join Date: Aug 2015
Location: Goleta, CA
Posts: 122
Sportster/Buell Model: XLH
Sportster/Buell Year: 2002
Other Motorcycle Model: KTM 380 MX-C
Other Motorcycle Year: 2001
Reputation: 83581
Cyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud ofCyclone14 has much to be proud of
Default

meanwhile, back in the garage... the previous owner despite only putting 419 miles on the bike had roached the LH rear turn signal. My parts stash yielded a NOS HD turn signal and a old unopened HD "running light" kit. I ordered some HD connecter parts from Ronnie's and a $18 crimp tool from Ramazon.



Reply With Quote
  #50  
Old 3 Weeks Ago
sportsterpaul's Avatar
sportsterpaul sportsterpaul is offline
XL FORUM LIFE MEMBER
 
Join Date: Jan 2009
Location: In a swamp/Michigan
Posts: 16,549
Sportster/Buell Model: XL1460C
Sportster/Buell Year: 2000
Sportster/Buell Model #2: XL1200R
Sportster/Buell Year #2: 2006
Other Motorcycle Model: XL1200R
Other Motorcycle Year: 2004
Reputation: 16741354
sportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond reputesportsterpaul has a reputation beyond repute
Default

That would be “character “ customization!
__________________
Pleasing everyone is impossible but pissing everybody off is a piece of cake!

Everything happens for a reason. Sometimes the reason is that you’re stupid and you make bad decisions.....

The XL Forum Sportsterpedia:
http://sportsterpedia.com/doku.php/start
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 02:57.


Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2022, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC