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  #1  
Old 3 Days Ago
ParrotHead's Avatar
ParrotHead ParrotHead is offline
I am the great Cornholio!
 
Join Date: Aug 2006
Location: Near Philly
Posts: 7,621
Sportster/Buell Model: 1200R
Sportster/Buell Year: 2006
Sportster/Buell Model #2: 1200R
Sportster/Buell Year #2: 2007
Other Motorcycle Model: Suzuki GT550
Other Motorcycle Year: 1974
Reputation: 6306769
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Default ParrotHead's 2019 Winter/Spring maintenance

Finally got a chance to start this thread. I actually started working on the bike a few weeks ago. This thread will document the maintenance on my 2006 Sporty.in preparation for the 2019 Iron Butt Rally starting June 17th.


My list of maintenance is as follows:


Replace starter
Try and solve my clutch woes (I hope)
Fix my exhaust leaks
Remove the Progressive fork cartridges and get them tested because they are too soft
Replace my rear bobtail fender with a standard fender
Replace the fuse box because the bottom tab for the left sidecover broke off
And anything else that I find while doing a 10K service


For anyone that is not aware, I have been having trouble with my clutch going out of adjustment in about 1,000 miles. It's been like that since I put the replacement engine in back in May 2017. At the time I had put in a brand new clutch hub, chain, and rotor/sprocket. Since then I replaced all the moving parts in the clutch assembly and the clutch pack itself. Next step is to replace the clutch hub.


First thing was to get the bike towed over to the shop where I work on it. That was actually done the Friday after Thanksgiving.

I got the bike up on the lift and pulled the primary cover and primary chain



I pulled the clutch hub so I could check it out. It does have a very slight wobble from the bearing. I'll replace it to be safe



Pulled the forks and had the cartridges replaced with the Progressive springs



I left the front fender off for now so I could clean the front wheel



Pulled the exhaust so I can pull the starter and replace the exhaust seals



Pulled and replaced the starter



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  #2  
Old 3 Days Ago
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Default

Im just trying to work up enough steam to put a set of chrome caps on my engine bolts.

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Default

I would add double checking your stator and regulator to the list so you know they are working 100% and not leave you stranded again.
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2002 XL1200C (originally)



Hammer 1250 kit W/ 30° reverse dome pistons, billet 2.25" crush forward offset open air cleaner, billet intake manifold, Impact 560's, Sledge Hammer pushrods, Buell XB heads with crush level head porting, Mikuni HSR 45, 177.5 main, 25 slow, Clip 4th slot from top, Jim's powerglide II lifters,
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Old 3 Days Ago
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ParrotHead ParrotHead is offline
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Join Date: Aug 2006
Location: Near Philly
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Sportster/Buell Model: 1200R
Sportster/Buell Year: 2006
Sportster/Buell Model #2: 1200R
Sportster/Buell Year #2: 2007
Other Motorcycle Model: Suzuki GT550
Other Motorcycle Year: 1974
Reputation: 6306769
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Quote:
Originally Posted by mikeLI_77 View Post
I would add double checking your stator and regulator to the list so you know they are working 100% and not leave you stranded again.
LOL, at the moment they are stock and I plan to leave it as is for now. They are working fine
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Chris, do consider adding the push button solenoid end cap, probably never need it but good to know it’s there should the need arise.
Which stock charging system did you go with, the original 22amp would be straining with some of your loading? I think the “police” and later injected are 30amp?
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ParrotHead ParrotHead is offline
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Join Date: Aug 2006
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Default

Quote:
Originally Posted by sportsterpaul View Post
Chris, do consider adding the push button solenoid end cap, probably never need it but good to know it’s there should the need arise.
Which stock charging system did you go with, the original 22amp would be straining with some of your loading? I think the “police” and later injected are 30amp?
I looked at the push button cap a few years ago and found that it would be difficult to reach due to oil lines and such. This was only my second starter failure

I currently have the stock one for my 06 which is 22amps. I was considering replacing with a 30 amp from an 07 or perhaps a Dyna setup like you had but with only 5 months to go I think I will leave it alone and go with what I have. With the LED lights I should be fine with either heated gear or aux lights. I should be fine with only one of those. I may grab an extra regulator as that is most likely what I'd burn out from over taxing my charging system
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