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  #341  
Old 23rd March 2017
Big Al's Avatar
Big Al Big Al is offline
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Sportster/Buell Model: XLH1200
Sportster/Buell Year: 1989
Other Motorcycle Model: Harley FLH1200
Other Motorcycle Year: 1974
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The tank is a steel King Sportster tank which I reduced in height, and flattened the sides and top - it's capacity is exactly 8 litres now, roughly 2.1 US gallons.
The motor weighed 153 pounds, and the frame was 43 pounds after I cut off all this stuff...
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  #342  
Old 30th March 2017
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Gary E Gary E is offline
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About the same tank capacity as mine. Not much weight of the pieces you removed from the frame, but the frame looks lighter than an '89 as their isn't as much material at the backend. Your tailpiece may be lighter, as mine is awful heavy with more material at the back end. I've drilled it full of holes everywhere I can under the seat and in the understructure without causing stress failure. It weighs 5 lbs. 3 oz. I've been considering making a mold and splashing one out of carbon fiber to knock off another 2 lbs. or so. Your bars look stock, so they are likely lighter than the wide Flanders I have. They weigh 3 lbs.
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  #343  
Old 30th March 2017
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Big Al Big Al is offline
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Other Motorcycle Year: 1974
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I'd have liked to use the Flanders 1" bars based on the XR750 curves, but their cost is prohibitive in Scotland, so used stock XR1200 bars instead, drilled to take internal wiring.
John Flanders told me that they made the original XR750's bars for HD, but that pipe bending machine they used then (2-1/4" radius bends) is no longer in service, and the new one has 2-1/2" radius bends, so the XR750 bars they sell these days aren't an exact copy anyway.
The XR1200 bars had roughly the same width, height, and clamp width as the original XR750 ones, the only real difference was a smaller pullback.
Some of the weight saving might be the 1970s Red Wing (Kayaba-made) 34mm road-race forks.
I measured the weight of the bike using an extremely slim digital bathroom scales, placed under each wheel, and under the jiffy stand, then added them all together - I'm confidant the weight is accurate...
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  #344  
Old 2nd April 2017
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The Flanders bar here are 32" wide and 10.5" pullback. If I recall original XR750 bars are 7/8" diameter. I wanted 1" so went with these at the expense of some weight. I'd really like to have utilized the carbon fiber bars I fabricated. Light weight and real neat looking, but they didn't work out. They are hanging on my shop wall.
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  #345  
Old 3rd July 2018
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HI Gary,

You mentioned using 15 inch shocks to get the proper stance with 19 inch rims. Are you measuring 15 inches center to center bolt holes un-installed or after installation sitting on the bike?

Regards,
Robin
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  #346  
Old 4th July 2018
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On the bike right now, they are 15" C-to-C.

Don't remember what the measurement is out of the box. I have a hunch it is also 15" since there is hardly any weight on them in the rear. I don't think the swing arm moves down any, or much at all when the rear is jacked off the ground. I did tighten them to the 3rd position after I hit a dip and tore the license plate and mount off when it hit the tire. Re-made the license plate mount with more angle, so no touchy anymore. It is a stiff ride.

They are Progressive Suspension #413-4039B. Got them from Phil Little.

Gary E.
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  #347  
Old 12th July 2018
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Been sometime since you started your hand on the steed.
May i ask the durability of results?
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  #348  
Old 12th July 2018
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Carbon Fiber fatigue, aluminium stress cycles and things you would change for instance.
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  #349  
Old 12th July 2018
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Quote:
Originally Posted by Ireeman View Post
Carbon Fiber fatigue, aluminium stress cycles and things you would change for instance.
I haven't had any issues to-date. Just got back from a ride this evening. The bike feels the same now as it did right after the completion of the build.

The chromoly swing arm is performing as it should. I've have some wet sumping when I let it sit too long between rides, a Harley thing, but have had no issues with the custom cycle parts. Rims, spokes, hubs, sprocket, flat track tires all doing as expected. All of the LED lights are performing at 100%. No fuel tank or seat/tail piece issues. Really like the low rear sets. Us old guys don't get much knee flex any more.

I did have to replace the H-D electronic ignition module a while back as it was internally breaking down. The bike would die right after starting it up. Took a while to solve the issue as it all seemed to be fuel/carb related. Turned out to be electronics. But this all H-D related, so doesn't have anything to do with the custom changes I made.

I currently have the carbon fiber oil tank cover off doing a surface re-finish of the clear coat. Up against the hot oil tank discolored the clear coat in some places.

Would like source a light weight starter. That stock H-D is a heavy piece of equipment. Don't think anyone makes one.

The lithium battery is going strong with no issues. Hardly ever put a charger on it.

I would have liked to have utilized the carbon fiber bars I made, but it just didn't work out. An experiment that now hangs on the wall of the shop. A conversation piece.

If I was doing it again, I'd make a mold of the seat/tail piece and splash one out of carbon fiber. That gelcoat boat glass is heavy stuff. A carbon fiber piece would weigh two or three pounds less. I would not change anything else.
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