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  #1  
Old 4 Weeks Ago
SprtyXL SprtyXL is offline
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Default Dual Speedo/Tach Gauge Mount Failure

My 1998 XL 883 destroys HD dual speedo/tach mounts about every 7-8k miles. The 4th one just developed a crack in the same place and broke through. Only the left side is holding the assembly to the bars now. The problem is the design and quality of the steel in the mount. The anchor points for the mount are atop the bar clamp and the entire weight of the assembly and gauges is supported by 2 allen head cap screws at either end of the mount base. Vibration places all the stress of the assembly on the holes and the lobes crack in half. All the replacements have been HD but this time I went with V-Twin mfg. hoping for better quality and thinking about making delrin washers to put under the mount to isolate the mount from the bar vibration. Has anyone else encountered this failure and come up with a fix?
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Have you tried to use large washers atop the mount?

Have you tried changing the handlebar bushings to polyurethane bushings?


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I resorted to large fender washers with rubber washers to distribute the vibrations more thoroughly and got greatly increased service from my 2000.
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Torque on the handlebar clamp bolts is only 12-15ft-lbs.
Too much torque can crack the cast speedo/tach mount at the bolt holes.
All things equal, the weight / vibration would break the casting near where the circle begins for the instruments.
Not where the mounting holes are at the bar.

Mine is original with no cracks.
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Thanks for the replies. Tried the larger washer route and both of the mount lobes broke at the same time and had to hold the gauge cluster to the bike by hand on the way back from a ride. Bar bushings are OEM.
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I've had several break on my 03 S model. I thought this was only an S model issue. The S model has an adjustable suspension and most S owners set it up firmer than regular front ends. It has been speculated that causes the bracket to break.

I think forum member Xena came up with a solution using two 1/2 inch drive 1/2 inch sockets with washers and longer bolts utilizing the headlight eyebrow mount. It happens to be the same spacing as the speedo/tach mount. I had one break there as well. I even had washers welded at the mounting holes. That broke too. Eventually the Speedo crapped out and the tach was jumpy. I replaced the whole thing with a Dakota Digital MCL3200 combo gauge as it was cheaper than the HD replacement. Years and miles later no problems.

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The fix is in. A sandwich of .062 neoprene washers both above & below the gauge mount to isolate the mount from the vibration. Handle Bar Clamp, stand-off, hardened 5/16 washer, neoprene washer to the underside of the mount. Mount. Neoprene washer, hardened 5/16 washer, cap screw. 12-15 ft. lbs. Lock-tite 260 on the H-D G-8 Cap screws. Fingers crossed.
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Quote:
Originally Posted by SprtyXL View Post
The fix is in.
Good Luck - Let us know if it works out.

Just be sure you have enough clamping pressure on the mount to keep the handlebars from rotating - especially in an emergency stop where you might be putting more pressure on them.

Ride Safe.

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Default Dual gauge mount failures are common.

I've seen a lot of posts about this problem but no real permanent solutions. I got a little information to share, however. It seems that many dual gauge setups are conversions. If all you do is take the dual gauge bracket and mount it on top of the upper handlebar clamp, it's going to fail. There are supposed to be stand-off spacers that are flat on the top but fit the curve of the top of the clamp. Now this could still fail because there's just not enough support to keep the bracket from flexing where it's bolted down. I've got a couple of ideas for permanent solutions and I will post them as soon as I get my new bracket and scope it out. There's also a top clamp that has a provision for the bracket. I still have to research all of this.

Incidentally, mine failed as a direct result of transitioning to the paved top coat of the road from a grated section under construction. It didn't look like much but it slammed when I went over it. Instant bracket failure.

If anyone hear has input on this, I'd love to hear it.
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