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General Category => General Discussion => Topic started by: analog kid on September 12, 2017, 06:00:29 PM

Title: 04 HD Sportster Roadster question
Post by: analog kid on September 12, 2017, 06:00:29 PM
Hi everyone,
Shortly, I will be going to see an 04 Sportster 1200 Roadster for sale. I'm starting my search on WG for previous threads, but I'm wondering about the drive belt. Was there a recommended replacement interval or is it on condition? I suspect this one is original and should I factor in belt replacement cost? Parts only, labour will be mine.

This bike has been sitting for at least a year, possibly 2. Belongs to a neighbour and is now part of her estate. So battery required of course, possibly tires and the usual mtc items. I've not seen it recently but rode it once in the past. I liked it. I also knew the owner and know a bit about its maintenance history.
Approx 48000 km / 30000 miles. That's not high mileage to me

It's the first year of rubber mounts and carbed.  Any problems stand out on this model?
I've owned a belt drive bike before and have no problem with it.
Thanks.
Title: Re: 04 HD Sportster Roadster question
Post by: fotoguzzi on September 12, 2017, 06:11:16 PM
my Buell belt was called lifetime, meaing if it breaks replace it, I did it preemptively at 20k. Belt>chain.
Title: Re: 04 HD Sportster Roadster question
Post by: Shorty on September 12, 2017, 07:05:37 PM
1200R gotta be one of the nicest looking HDs in recent years. Unless you damage it somehow, the belt is a long term item. Not much to go wrong on a rubber mount Sporty, if the PO didn't modify it too much. I had a 2004 , and my complaints were fuel consumption, top heavy handling, and a vibration I could not get used to right in the sweet spot of 60-80 mph. Other Roadster owners have not shared my experience. I think they will be sought after in years to come. Enjoy it.   :thumb:
Title: Re: 04 HD Sportster Roadster question
Post by: SemperVee on September 12, 2017, 07:19:17 PM
   I would own another sporty in a minute.  That or the 2012 sports model.
Title: Re: 04 HD Sportster Roadster question
Post by: arveno on September 12, 2017, 07:56:47 PM
I am not sure but if i remember correctly HD recommend to replace the belt at 75 K miles ? ( as preventive maintenance but it could last 100 k and more. )

I will not be too concern about the belt thought , just inspect it and if the are no cracks  , i would just ride it.

if the bike was properly stored it should last forever....

Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on September 12, 2017, 09:13:30 PM
I could be wrong and I'll check the maintenance schedules tomorrow to be sure, but I don't recall ever seeing a belt replacement interval.

If not overtightened, contaminated by oil, or cut by a stone, they should last more than a decade or 100k easily.

Anyway the 04-06 rubbermount 1200R bikes are fantastic models. They are overcooled, under-stressed, and generally very hearty.

My buddy Chris has completed two IBR's on his 06 1200R, and that was AFTER it already had 200k+ miles on it.

Granted, he did replace the engine after 225k or something like that, but it seems it was likely because of a botched rebuild which was undertaken only because of a single roller bearing that was failing.

Anyway if you pick it up just do some basic maintenance (fluid, filters, battery if needed) and assess from there.

Oh, btw, on mine I went down a size on the rear tire 150-->140, but up a size on the front 100-->110.

The rear quickened turn in, the front just felt better balanced.

Good luck.

(https://uploads.tapatalk-cdn.com/20170913/e89da39be8ac9e3e61f92a58eea2d29e.jpg)
Title: Re: 04 HD Sportster Roadster question
Post by: yogidozer on September 12, 2017, 09:19:17 PM
lots of info on sportys here http://www.xlforum.net/vbportal/forums/index.php
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on September 12, 2017, 09:48:00 PM

I will not be too concern about the belt thought , just inspect it and if the are no cracks  , i would just ride it.

if the bike was properly stored it should last forever....

Yeah, I was once the second set of eyes on a 97 Heritage a friend was interested in. I was all over the belt for condition, which was good. Too bad I didn't notice the rear wheel was at its adjustment limit. D'oh!
But he bought it and the belt never gave him trouble, so I'm not overly concerned.

The seller has not responded yet, so no inspection.

Some details:
I asked if they kept the stock pipes which I will reinstall in place of the V&H 'mufflers' the owner put on. 
Don't know if the jetting was messed with.
Has a Mustang seat which the PO said really increased her ride time from the stocker.
HD quick release windscreen
Heated grips
Soft sidebags
Crashbars......
Was owned by a first time rider, so it's been driveway dropped a few times. When I rode it, the handlebars were slightly bent, I assume from a drop. The owner had not noticed.

Thinking about it now, the bike might turn out to be a bit ratty. Not abused, but not cosseted either. It was ridden (slowly) and basically maintained, but I never did see her wash it.
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on October 14, 2017, 08:35:10 PM


If not overtightened, contaminated by oil, or cut by a stone, they should last more than a decade or 100k easily.

Oh, btw, on mine I went down a size on the rear tire 150-->140, but up a size on the front 100-->110.

Cue my Mr. Burns voice: Eeeeeeeeexxxxxxxcee ellent
Tire sizes noted KevM.
I will be buying tires for it.....2/32 - 3/32 tread remaining on the Dunlop D401s.

Bought it this afternoon, but have not ridden it yet due to licensing & no insurance.

Very very fair price, Mustang seat, leather saddlebags (maker unknown), HD windscreen, heated grips, the owner threw in a bike lift - which I have already, but can sell it to put into tires. Battery checks ok, has been on a Tender while stored.
Per the owners manual, it's time for its 48000 km maintenance check. Most of that stuff I do anyways when buying a new bike. HD says it's time to replace the swing arm bearings, that's the only unexpected maintenance item, but no big deal.

Has been maintained but not cosseted. One broken pipe mount is all I've found so far.
Needs mufflers. The V&H mufflers have nothing by way of baffling. I'm not interested in cracking the neighbors windows upon start.
 Carb throat is black. I don't know if it was rejetted when the stock mufflers were replaced. Either way , it's running rich. Will get into the carb to see what jets are in there. Plugs are black too.

One minor blister on top of fuel tank; looks like a brake fluid drip when refilling ft. brake reservoir.
As much as I make (made ?) fun of Harley riders and their polishing obsession, this afternoon I mentally noted that I have a can of Chrome cleaner in storage and......will be using it.

I don't have a picture host, so can't post a pic yet.

Thanks all for posting info , I'm sure I'll enjoy the ride!
Title: Re: 04 HD Sportster Roadster question
Post by: fotoguzzi on October 14, 2017, 09:34:07 PM
on the reply page lower left, you can use "add image to post" and use a pic right from your computer- no host needed.


(http://thumb.ibb.co/f9RiRG/IMG_1994.jpg) (http://ibb.co/f9RiRG)
Title: Re: 04 HD Sportster Roadster question
Post by: Shorty on October 14, 2017, 10:20:39 PM
Stock mufflers are pretty cheap on Flea bay. Local dealer might have a stack of them as well.  :grin:  if not already equipped, one of these extended mixture needles is a nice addition to the Sporty. Allows you to adlust mixture without needing skinny fingers and a tiny screwdriver. You may need to remove the blanking plug on the mixture screw.

https://www.jpcycles.com/2004-harley-davidson-sportster-1200-roadster-xl1200r/carburetor-jets-and-needles/cv-performance
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 15, 2017, 06:44:50 AM
Sweet. Let me know if you need any tech info.
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on October 15, 2017, 11:49:07 AM
on the reply page lower left, you can use "add image to post" and use a pic right from your computer- no host

Ah, well then:

(http://thumb.ibb.co/hpsid6/20171014_123409.jpg) (http://ibb.co/hpsid6)


And unlike the others, no one will ask me : "who makes that?"
Title: Re: 04 HD Sportster Roadster question
Post by: blackcat on October 15, 2017, 12:38:12 PM
Good luck with the bike, very nice looking.

I had a Sportster(89?) for a few years, always enjoyed it and I assume the newer models are way better than mine. 
Title: Re: 04 HD Sportster Roadster question
Post by: SmokinJoe on October 15, 2017, 08:28:45 PM
I like mine.
(http://thumb.ibb.co/cKFyd6/2017_03_19_19_35_33_478.jpg) (http://ibb.co/cKFyd6)
 
Mine is 07 883r so FI. Added bigger tank, different seat as you see. On the carb model i'd hope it was stored properly, if not you may have some issues that are hard to overcome without a replacement. Everything else should be fine. The one I have sat for a couple of years as well with no issues except battery and hard/aged tires. But good luck may prevail. This pic is at the end of a 500 mile day and was still feeling good. So how much better does it get?
Title: Re: 04 HD Sportster Roadster question
Post by: Shorty on October 15, 2017, 11:00:22 PM

(http://thumb.ibb.co/nva6Fm/57.jpg) (http://ibb.co/nva6Fm)


My 04 1200R. Long gone.  :grin:
Title: Re: 04 HD Sportster Roadster question
Post by: Muzz on October 16, 2017, 05:26:08 AM
My son owns a 2002 Sporty, his 4th. (He will only have the Sporty in the HD range) He carries a spare belt. The advantage with the Sporty over the big blocks evidently is that you do not have to disassemble the clutch to fit a new belt. He intends to ride it until it goes bang, then replace it.

The fact that he carries a spare means it will never go bang.... :popcorn: :popcorn: :rolleyes:
Title: Re: 04 HD Sportster Roadster question
Post by: dxhall on October 18, 2017, 06:36:24 PM
Kev - what's the appeal of 2004 - 2006 bikes?  I know that '04  was the first year of rubber engine mounts, but what changed with the '07 models?
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 18, 2017, 08:02:01 PM
Kev - what's the appeal of 2004 - 2006 bikes?  I know that '04  was the first year of rubber engine mounts, but what changed with the '07 models?
04-06 were carbureted but they contained the greater cooling fin surface area and new piston oil jets etc. that were designed to keep the soon to come hotter running EFI motors cool. So they are very robust.

The 07 was the first year for EFI.
Title: Re: 04 HD Sportster Roadster question
Post by: dxhall on October 18, 2017, 08:34:02 PM
There's an '05 for sale near me, 4000 miles, $4500 asking price.  Thoughts?
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 18, 2017, 08:37:12 PM
There's an '05 for sale near me, 4000 miles, $4500 asking price.  Thoughts?
If you like it then I think it's a decent bike for the money (though I bet you could get it under $4k).

I always compared my 07 to my Jackal in a lot of good ways.

As a matter of fact I rode my 07 today because I was missing it.

Let me know if you have specific questions. And if you ride it what you think of it.
Title: Re: 04 HD Sportster Roadster question
Post by: davevv on October 18, 2017, 10:49:41 PM
Congratulations on the purchase.  They are great bikes.  I bought my '04 Roadster a little over four years ago, which means I've owned it longer than any other bike I've had in 56 years of riding.  Finally upgraded the suspension with Progressive 444 rear shocks, Intiminators in the forks, and a fork brace this year.  Better than ever!
(https://photos.smugmug.com/Motorcycles/Marques/Harley-Davidson/XL1200R/i-f29NbCb/0/02ca3cf8/XL/DSCN0003-XL.jpg)
Title: Re: 04 HD Sportster Roadster question
Post by: MMRanch on October 19, 2017, 12:01:07 AM

(http://thumb.ibb.co/myUfT6/0217171700b.jpg) (http://ibb.co/myUfT6)
Ive had two Harleys , both Sporters , one a 2004 -1200 Roadster ,  Its' fast and a little top heavy and vibrates in the sweet 70-80 mph range .   

The second one I still got , a 2007 883 , not so fast (but fast enough) , a little top heavy , and velvety smooth.   :cool:

apparently HD built the 883 and got it perfect , then as an after thought ...  :boozing: ... put the bigger pistons in it .   Well , its "good" but no longer "perfect" .
Plan on using 93 octane in your 1200 ...  :wink:

No , that's not the original paint   :cheesy:


If I ever buy another HD , it will be a : 2004 -2006 --- 883 .   :smiley:

 
Title: Re: 04 HD Sportster Roadster question
Post by: Moto on October 19, 2017, 12:14:52 AM
If the left (port) side of the Sportster Roadster's motor looked like the right side, I would be dying to get one.

As it is, I can't imagine how you could turn left on it, with that clutch casing sticking out like it is.

I guess you could circle around the block to your right and make a left turn that way.

Moto
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 19, 2017, 05:25:59 AM
Two things:

* It shouldn't need 93, it's only spec'd for 91.

* The clutch doesn't stick out very far. The Sportster is a narrow, unitized crankcase design.
Title: Re: 04 HD Sportster Roadster question
Post by: Rough Edge racing on October 19, 2017, 05:50:40 AM
   Talking to Harley guys it seemd that the belt life is very different for each bike and each rider...What I do hear is if a small stone gets in the belt ,failure is soon to happen.....In my opinion, the stock Sportster dual pipes should be thrown away and the bike fitted with a proper two into one exhaust like a Buell, but not exactly the same obviously...That and on proper air cleaner on a carburated Sportster is good for 15 HP without an increase in noise....From my experience on a Buell, the Mikuni 42 MM flatslide was also an improvement in performance and fuel mileage compared to the stock  CV carb...The Buell has slightly higher compression and had no problem with 91 octane non ethanol gas...
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 19, 2017, 06:24:42 AM
   Talking to Harley guys it seemd that the belt life is very different for each bike and each rider...

I don't know that I'd say it's very different for each bike, it really depends on 3 things:

1. Use - lots of dirt and gravel means you'll pick up a stone at some point, and if not found, eventually a failure.
2. Adjustment - too tight is not right.
3. Oil/Chemicals - contamination will eventually lead to failure.

I think it's way more common that owners never replace a belt, and there are plenty that make it past 100k miles.

I do have a little bit of stone damage on my current belt at 30k miles, but no plans to replace it.
Title: Re: 04 HD Sportster Roadster question
Post by: Rough Edge racing on October 19, 2017, 07:47:56 AM
I don't know that I'd say it's very different for each bike, it really depends on 3 things:

1. Use - lots of dirt and gravel means you'll pick up a stone at some point, and if not found, eventually a failure.
2. Adjustment - too tight is not right.
3. Oil/Chemicals - contamination will eventually lead to failure.

I think it's way more common that owners never replace a belt, and there are plenty that make it past 100k miles.

I do have a little bit of stone damage on my current belt at 30k miles, but no plans to replace it.

  Yes on the too tight....On the tube frame Buells the factory belt tightness recommendation leads to early belt  and transmission high gear bearing failure...The proper adjustment is quite loose, about two inches easy play on the top run with the rider seated......A Sportster has different swingarm motion than a Buell but the loose belt is better than tight...
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 19, 2017, 07:59:35 AM
  Yes on the too tight....On the tube frame Buells the factory belt tightness recommendation leads to early belt  and transmission high gear bearing failure...The proper adjustment is quite loose, about two inches easy play on the top run with the rider seated......A Sportster has different swingarm motion than a Buell but the loose belt is better than tight...

 :thumb:

Same thing on Sportys (and probably most Harleys), i.e. the factory spec is tight.

Also early on in the rubbermounts some guys who were running them too tight (at factory spec or tighter) were getting some effect in the suspension from it. Some guys took off the rear shocks and moved the swing arm through the arc and found just how tight it was getting at the tightest point in the arc and realized they needed to loosen them up. This eliminated any effect on the suspension from the belt binding at that point in the arc.

Basically the taller the suspension and longer the arc the looser the belt needs to be (as seen in the specs) and then add another couple of 1/8th's for good measure.

 :bike-037:
Title: Re: 04 HD Sportster Roadster question
Post by: Tom H on October 19, 2017, 01:18:05 PM
Looks like I need to loosen the belt on my Street Bob. I adjusted it per the book with a belt tension tool. Don't know how accurate I was though.

Does anyone know what #'s the belt should be, or how many inches it should move with the bike in a front wheel chock and no rider weight? I would need to measure from below where my sight hole is.

I ask because sometimes on rough pavement the bike almost has a vibrationy type feel while the suspension is working. Maybe the belt is too tight?

Thank you,
Tom
Title: Re: 04 HD Sportster Roadster question
Post by: MMRanch on October 19, 2017, 11:54:37 PM
Yea Tom

If you'll strap the rear down and compress the rear shocks till the swing arm pivot point , center of front pulley , and the rear axle are all in a strait line ... then , that will be the longest distance the belt will ever need to stretch too.   Adjust it at that point and don't worry about how loose it is when you let the rear shocks loose !  :wink:

I've got 38,000 + miles on my Harley belt and it still looks and feel like new .  :grin:     I got a buddy just north of San Antonio who has over 160,000 miles on his LS-650 belt.  My LS-650 has over 42,000 on it's belt.   

Amazes me that Honda still uses "CHAINS"  :sad: 
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 06:53:36 AM
Yea Tom

If you'll strap the rear down and compress the rear shocks till the swing arm pivot point , center of front pulley , and the rear axle are all in a strait line ... then , that will be the longest distance the belt will ever need to stretch too.   Adjust it at that point and don't worry about how loose it is when you let the rear shocks loose !  :wink:

That's probably the best/most thorough way to figure it out.

Me, I'd probably just loosen it up a bit (5-10 mm out of spec) and take it for a test ride.

Title: Re: 04 HD Sportster Roadster question
Post by: bacongrease on October 20, 2017, 08:09:28 AM
posted before, one guys opinion, so take it as it is.....


http://www.jamesrussellpublishing.biz/sportster1200.html
Title: Re: 04 HD Sportster Roadster question
Post by: Rough Edge racing on October 20, 2017, 08:16:16 AM
 I also prefer a chain drive ....But...I swapped from a belt to a chain on my 97 Buell....I also changed the overall ratio more to my liking...But on late Sportster engines there is no cush drive on the driveline...In certain situation there was an odd vibration I didn't like...I sold the chain conversion for what I paid for it and reinstalled the belt with a different front pulley to change the ratio....The pulley was about 150 bucks...Riding a tube frame Buell with carefully tuned engine will change your mind about "agricultural " Harley engines.

         
            (https://i.imgur.com/qk3P83bl.jpg)
         
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 08:27:17 AM

This might be a reason...
I helped a friend of mine change the belt on his (RK I think)that had about 50K miles. We used my stand and had to remove the primary case the clutch the rear swing arm. Took half a day!
Also since the 6th gear is almost useless while cursing down the slab at anything but flat road and less than 85 mph he looked into changing the ratio to something low enough to make top gear useful but the cost of new sprockets gave him pause and he passed.

If you do your own maintence its a factor to consider.

No, actually it's not. The fact that the BT's are set-up that way has nothing to do with whether or not a belt NEEDS to be set up that way (see the Sportster with the right side drive belt instead of the left/primary setup on the BTs).

And you probably will never NEED a sprocket, that's why costs are high, because they don't generally need to be replaced or swapped.

I have no problem with the ratios in my RK.


posted before, one guys opinion, so take it as it is.....


http://www.jamesrussellpublishing.biz/sportster1200.html

Well it's just as stupid now as it was then.

As a career professional in the publishing industry I have a real problem with this near illiterate calling himself a publisher.

The verbal vomit on that site (which you are helping to promote) is nothing more than a horribly disingenuous attempt at drawing traffic to his site for his own promotion.

Most of the tech crap is way out of date and drastically overstated.

Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 09:31:41 AM
Quote
"No, actually it's not. The fact that the BT's are set-up that way has nothing to do with whether or not a belt NEEDS to be set up that way (see the Sportster with the right side drive belt instead of the left/primary setup on the BTs).

And you probably will never NEED a sprocket, that's why costs are high, because they don't generally need to be replaced or swapped.

I have no problem with the ratios in my RK. "


I don't really understand that.

Pulling what I described was required for changing the belt. Also if you change the ratio then you have to get a custom sprocket,(probably the rear) and chances are a custom length belt. I don't want to start a debate about the merits of the system, just explaining what we had to do to change the belt and demonstrate why a chain isn't all that bad. Anybody that changes the belt like I have described should really have some mechanical ability as well.

As far for the 6th gear, I have ridden the machine and it would not pull 80 mph up slope on the slab without down shifting to 5th and he many times runs in 5th at 80 which gives him better mileage.      (operation mostly at 4,000+ above MSL out west.)

That is why he looked into changing the rear ratio. This machine is in good nick and has good power.


OK, let me try again.


You used this story as an example why in your opinion chains are better than belts.

My answer was that your story doesn't prove that, the fact that is is a belt and not a chain has nothing to do with it. The belt does NOT have to be placed behind a primary, that all comes down to transmission design.

The belt on a Sportster is on the RIGHT SIDE (not behind the primary on the left like that RK) so all you need to do to access it is remove the belt cover (and possibly part of the rear exhaust pipe depending on the setup).

So no - the mere fact that a belt is used does not require all that labor.

Your story is really about a specific design trait of the Harley Big Twins, one that I'm not sure why they persist with, but probably because belt replacement IS SO RARE.

As for 6th gear, I have no idea of the year or state of tune, it could be a TC96, but my TC103, stock fueling is geared just fine, I wouldn't change the rear sprocket (or primary) in search of different gearing. Your friend might just downshift to 5th on a slope no or lose a couple of pounds no?

But yes, in that specific instance, if he is looking to change the belt, that specific design does make it more work than it needs to be.

Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 09:54:49 AM
No my post was to answer the question "why does Honda still use chains :embarrassed:

My answer "This could be one reason"

Had nothing to do with debate on chains v/s belts.

I guess we're having communication difficulties this morning.

Isn't the question "Why does Honda still use chains" equal to "Why does Honda think chains are better than belts"?

Your post about ease of replacing a belt has nothing to do with it being A BELT. There's no reason a belt HAS to be harder to replace than a chain. So that has nothing to do with it.

Maybe the rest of the post touches on a reason. The only advantage a chain has over a belt (except in very high hp applications) is that you in theory can change a sprocket and shorten a chain (without replacing it) and chains tend to be a cheaper than belts (though you should expect to replace chains and sprockets multiple times over the life of a belt).

But yes ratio changes might be easier.
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 10:13:15 AM
Ah, yes, sorry, I see what you mean.

And yeah YMMV - ambient conditions certainly would play a part.

But man, if I never buy another bike with a chain, that would be ok with me.

Title: Re: 04 HD Sportster Roadster question
Post by: Rough Edge racing on October 20, 2017, 10:16:43 AM
  Chains are  about 1/3 the width of a belt that can be be an advantage with tight packaging of components....belts won't work well in situations where debris can get between the belt and pulley......And in my mind, a chain has a mechanical look to it and looks cool... :cool:
Title: Re: 04 HD Sportster Roadster question
Post by: oldbike54 on October 20, 2017, 10:40:52 AM
 All fine and good , but who makes that ?

 Dusty
Title: Re: 04 HD Sportster Roadster question
Post by: oldbike54 on October 20, 2017, 12:01:48 PM
I'll take that to mean the  consumer?

Well my guess is that only real enthusiast really pay much attention or care what kind of final drive system the machines have.
We gear head types will always debate the merits of each .

Given the choice?? Depending on the foreseen use/configuration/climate, I would prefer a chain drive. Efficient and inexpensive. Having said that though, I'm stuck in the middle with you guys it seems.

:-)

 Sorry Mike , was referencing the comment made earlier about no one asking "who makes that" . Should have clarified it a bit . Quite honestly , every HD I have ever ridden felt numb and disconnected from me , except for the 1939 EL that belonged to a friend , that thing let the rider feel everything  :shocked:

 Dusty
Title: Re: 04 HD Sportster Roadster question
Post by: Lesman on October 20, 2017, 02:10:07 PM
I had a 2006 1200R. Gas mileage should not be an issue. Tank range could be an issue. I had a 1991 1200. After mods it could get down to a 50 mile range if you rode in anger.  2006 1200 got a consistent 40+ mpg. It had great brakes compared to my GSPD. The brakes on mine were very good . Rear shocks were the absolute worst examples of any bike that I ever owned. Honda 90 had better rear shocks. The seat is really thin. I had the world's loudest exhaust. Quiet is better.
I had a quick release windshield. It's a great bike except for the rear shocks and seat.
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on October 20, 2017, 03:37:24 PM
I had a 2006 1200R. Gas mileage should not be an issue. Tank range could be an issue. I had a 1991 1200. After mods it could get down to a 50 mile range if you rode in anger.  2006 1200 got a consistent 40+ mpg. It had great brakes compared to my GSPD. The brakes on mine were very good . Rear shocks were the absolute worst examples of any bike that I ever owned. Honda 90 had better rear shocks. The seat is really thin. I had the world's loudest exhaust. Quiet is better.
I had a quick release windshield. It's a great bike except for the rear shocks and seat.
Thanks for posting.
I figured tank range would be an issue. I had a sportbike with a small tank and an appetite for fuel. That was one reason I sold it. I figure there are bigger tanks available if range becomes an issue.

In my 1.5 hours of ride time so far I found the rear shocks not as bad as I thought they would be, but yeah, they're cheapies.
Surprised at the engines ability to rev. It's easier to blip for a downshift than on my Mille. Must have a lighter flywheel. But then the Titanic had a lighter flywheel than the goose.
Took awhile to acclimatize,  I began by driving it like a guzzi - revs and working the gearbox. Bad effect. I was gnashing gears all over the place. Better now.

Since I don't yet have a service manual, can anyone tell me if there should be free play at the clutch lever? Mine has zero free play,  clutch works well though. Owners manual has no info on that. Lube cable or no? It's a mighty pull.

And how's the Clymer service manual for the 2004 and up Sportsters? Good enough or invest in Factory $ervice manual? I wont be overhauling, just all regular maint.
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 20, 2017, 03:59:26 PM


Thanks for posting.
I figured tank range would be an issue. I had a sportbike with a small tank and an appetite for fuel. That was one reason I sold it. I figure there are bigger tanks available if range becomes an issue.

In my 1.5 hours of ride time so far I found the rear shocks not as bad as I thought they would be, but yeah, they're cheapies.
Surprised at the engines ability to rev. It's easier to blip for a downshift than on my Mille. Must have a lighter flywheel. But then the Titanic had a lighter flywheel than the goose.
Took awhile to acclimatize,  I began by driving it like a guzzi - revs and working the gearbox. Bad effect. I was gnashing gears all over the place. Better now.

Since I don't yet have a service manual, can anyone tell me if there should be free play at the clutch lever? Mine has zero free play,  clutch works well though. Owners manual has no info on that. Lube cable or no? It's a mighty pull.

And how's the Clymer service manual for the 2004 and up Sportsters? Good enough or invest in Factory $ervice manual? I wont be overhauling, just all regular maint.

2-3 mm off play at cable end, measured at cable housing when pulling it lightly back from the perch is fine.

But there is more to it than that for a full adjustment (there's a ramp screw under the Derby cover that controls clutch ramp release point).

You can lube cable ends but it won't make a difference in the pull.

Don't waste your money on the Clymer.

If you're not going to buy the one from www.cyclepedia.com (the carb one is pretty damn good, I used a good bit of it when I wrote the EFI one for them), then go OEM.
Title: Re: 04 HD Sportster Roadster question
Post by: MMRanch on October 20, 2017, 10:51:36 PM
Guys

For one of my bikes I have two front pulleys (two teeth different) .   to change belts , all it takes is :
remove the rear shock on the belt side ,
loosen the adjuster
remove side cover over F/pulley
slide the belt off

less than an hour ...  :grin:

Adjust it one time for the life of the Rear Tire , never any messy oil/wax/anything  :grin:

As Kevin said :  "But man, if I never buy another bike with a chain, that would be ok with me."



 
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on October 25, 2017, 11:19:43 AM
Last weekend, Oct 21, was the first (and probably final for 2017) meeting of the Creaky Knees Motorcycle Club.

In honour of the approaching Halloween, we rode past cemeteries in an effort to raise the dead with our insufficiently muffled bikes. It worked, I saw zombies.

For a change, my riding buddy rode south to meet me at my house for the ride - which never happens, usually I ride 40 minutes north to meet him at his place. I think he was just excited to ride my bike.

He pointed out a couple more non-stock details like the LED taillight. I knew the red cover had been changed for smoked, but had not noticed the LEDs underneath. Its not impressive. The running lights in the rear turnsignals are brighter than the taillight, and the brake light is insufficient. Added to the change list. 

(http://thumb.ibb.co/nnu35m/DSCN7071.jpg) (http://ibb.co/nnu35m)

(http://thumb.ibb.co/heLt5m/DSCN7070.jpg) (http://ibb.co/heLt5m)
 
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on October 25, 2017, 11:48:33 AM
You should be able to score a take-off tail-light cheap. The LEDs are a bit overkill on a charging system that's fine and a bike that already has the plug-n-play additional running/tail-light kit for the turn signals.
Title: Re: 04 HD Sportster Roadster question
Post by: analog kid on June 29, 2019, 12:12:30 AM
Since I started this thread, I figured I'd finish it off.  End-of-chapter, so to speak.

CAUTION:  long post.  :copcar:

I've got a rainy evening, time to kill,  and a bottle of wine - watch out!  :boozing:

I got the bike back on the road. Bought in Oct 2017, from the estate of the woman who lived across the street. Got a good price because I knew the family, and the bike was sold as-is. It wouldn't have passed a safety check for registration. 

I was there when she took delivery of the bike, worked on it a couple of times when she had maintenance issues, rode with her twice and test-rode the bike once. That was after the Harley crowd told her the bike had no power and was unrideable without loud pipes  :rolleyes: . I disagreed; thought it was a very fun ride and its power was just fine.
She went with them....

It ran, but had been stored a couple of years. It needed garage time and a cash infusion. I picked away at it through the summer of 2018, but didn't have the time to devote to it. I began work in earnest in Fall 2018, slowed down through the coldest winter months, then finished off in May. 
Got it street plated and am now riding it whenever I can. 

It had been slightly chopperized, so had to undo that. 
2 new tires to replace the circa 2006 Baldini Specials. 
New handlebars to replace the bent buckhorns. Parking lot drop by the PO. 
New grips.
New front brake light microswitch...due to <ahem> ...current owner induced damage.
Clutch disassembly to check for wear. All good.
Completed all the sched maintenance work up to current mileage, since the bike came with no maintenance history...though I would have done all that anyways.... :grin:
Fork oil, engine oil, brake fluid change. Pulled all the calipers, cleaned everything up. Pulled the swingarm , cleaned everything, bearing check. 
Bought used, stock mufflers to replace the unbaffled V&H Straightshots previously fitted. Fiddled with jetting, which was stinking rich (literally stinking!). Wish I knew which shop she took it to, so I don't go there...

Ya, I have the planet's rarest commodity: a quiet Harley. And that's exactly how I want it.

The biggest niggle was that the bike had been worked on by lackadaisical people who didn't give a crap. It had quality add-ons, but previous work was careless : spacers missing, washers missing, grommets missing, incorrect bolts installed, and my pet peeve: stripped threads and damaged hardware. 

I spent alot of money simply on hardware. At least Harley hardware is cheap. 

Mongo worked on this bike in the past. Mongo like big torque on little fasteners. Put down the impact wrench Mongo! 

I removed the crash bars; I appreciate them for function, but don't like the look. And I'm aware the wide Mustang seat looks out of place , but it's so much better than the stocker.

So, after all this, I'm a hair away from posting it for sale. It's cleaned, the pics are taken, I just have to write the ad.

I love the bike, it has a lot in common with an old Guzzi,  but....circumstance s.

It needs money put into suspension - cheap dampers when new (front & rear) don't get better after 50000km. I'm not a city rider or barhopper.  Rideability is paramount. 
Riding at twilight last week, I hit an unseen frost heave in a curve and damn near left the road. My spine protested mightily.

The conundrum:  with limited cash to spend, should it go to the HD or into the Guzzi Mille? Or better yet, into my LM 3 project which I've left unattended far, far too long. And how long can I store a bike in my mother-in-laws garage because I have run out of space in my own?  :laugh:
Also, plating and insuring one less bike is a consideration.

So my HD interlude may be ending for now. It was an education.I enjoyed it.  I'd do it again with the right HD model......(XLCR, XR1000, XL Roadster, my friends 5000km '91 FXR - owned since new....you get the idea)  :thumb: I never worked on an HD before. I learned stuff (that's a whole other thread!).

One day ago (27 june)  I fired up the Mille from winter storage. I'd been busy all spring with the HD , and the weather was crap anyways. Riding both bikes back-to-back was a riot  :bike-037:. Turns out I had gotten used to Harleys two-button turn signal switches (one switch on right, other on left) which I had cursed initially. The Sportster has better brakes, or at least, better feel. And in spite of its weight, it's an easy bike to pull out of the garage and ride away. Nice low end torque . A low seat - which i didnt used to care about....but my bad knees do.

A lot to like..

(https://i.ibb.co/8NHjYnh/20190626-150603.jpg) (https://ibb.co/8NHjYnh)

(https://i.ibb.co/VNwJN2g/B-A-Station.jpg) (https://ibb.co/VNwJN2g)

(https://i.ibb.co/VtxCBRg/Ganaraska.jpg) (https://ibb.co/VtxCBRg)

(https://i.ibb.co/hVLjKxt/20190429-101651.jpg) (https://ibb.co/hVLjKxt)

(https://i.ibb.co/HXWZNPN/Mille-charging.jpg) (https://ibb.co/HXWZNPN)

upload photos (https://imgbb.com/)
Title: Re: 04 HD Sportster Roadster question
Post by: Kev m on June 29, 2019, 06:46:21 AM
 :thumb:

Great report.

Life is good.

Ride safe!

Title: Re: 04 HD Sportster Roadster question
Post by: s1120 on June 29, 2019, 09:23:51 AM
All in all it looked like a fun project. I had looked at getting a sportster when I was shopping. I had avoided HD's at first, because it wasn't really what I wanted...  But you cant beat the huge used market, and parts, and info are EVERYWHERE!!  I saw that a sporty could fill my needs. But you know... a Guzzi was the right bike, and what I really wanted. You got some nice bikes to work with.. a few bucks from the sale of the sporty put into the others might be a good thing. And as you said.. you learned a lot also.
Title: Re: 04 HD Sportster Roadster question
Post by: Rough Edge racing on June 30, 2019, 11:02:18 AM
 I bought a 2001 883 Sportster a few months back as some of you know...I bought it because of the very low price and it looked good...I like the bike but it has one very bad problem...It is without a doubt the most uncomfortable bike I have ever owned.I'm 6 foot 175 pounds.The low seating postion, it is not a hugger model, along with the mid postion foot rests makes me feel like man on a kids bicycle...I sold the LePera seat and found a modified stock seat with extra padding..Better but it still sucks.. I fabricated a set of rear set pegs and controls similar in design to Sato.. Now it's a much better bike... .I also blew a pile of money on a 2-1 Supertrapp exhaust, a set of Koni shocks from a Guzzi that are the correct length and spring rate. I pulled the front springs, cut off most of the tight wound "progressive" coils, made a longer spacer..... What a difference in back road performance...I will have photos shortly...
Title: Re: 04 HD Sportster Roadster question
Post by: EldoMike on June 30, 2019, 04:44:07 PM

(http://thumb.ibb.co/nva6Fm/57.jpg) (http://ibb.co/nva6Fm)


My 04 1200R. Long gone.  :grin:

I bought this bike from Shorty (seems I buy something from him every few years) ..I really liked it but did seem to have a vibration...didn't keep it long enough to figure it out but would buy another rubber mount Sporty (and I have)...
Title: Re: 04 HD Sportster Roadster question
Post by: Shorty on July 01, 2019, 03:12:25 PM
I bought this bike from Shorty (seems I buy something from him every few years) ..I really liked it but did seem to have a vibration...didn't keep it long enough to figure it out but would buy another rubber mount Sporty (and I have)...

Stay tuned. You never know when I will come to my senses and have another purge.  :grin: