My Worst Day Wrenching...

[101ABN]

So I finally got my pullback bars, my braided stainless cables and my new MoCo grips and decide after reading all the posts on the Sportster board that it will take a little time but won't be all that difficult. After all, I have my service manual and lots of tools and the whole freakin' day to tinker away.

I start by removing the right hand grip and and the upper end of the throttle and idle cables. So I turn next to remove the bracket that holds the master cylinder. The fucking screw is a TORX 27. I have three sets of TORX sockets plus the L-shaped wrenches and not a fucking 27 in the bunch. Off I run to the local hardware store and buy another set of the little bastards with a cool 1/4" drive reversible ratchet. I get home, rip open the package, load it up and when I apply a little pressure to it, the fucking socket head twists up and now looks like threads on a fucking screw (made in China).

I take the fucking nifty little set back and head for Sears. Of course it's 13 miles away on the other side of the hill. When I get there they have no 27's. Don't even carry them except in a fucking set and they're out of the fucking sets.

Off now to my friendly NAPA store where I buy their last 27 socket and head back over the hill for home. All this, plus an errand or two has now eaten up four and a half hours.

So I get home and load up the new 27. One screw breaks loose and I'm thrilled to be finally moving forward. I engage the next screw and it won't budge. A little penetrating oil, and a little more elbow grease...and the fucking head strips out.

I'm not ready to let a little thing like this set me back, though (ever the eternal fucking optimist). I figure I'll just remove the left side stuff, unbolt the bars and slide the master cylinder and switch housing off the old bars and onto the new ones. I twist down on the left side and that fucking head strips.

Well, this is more than I'm ready to deal with. I figure I'll just put it back together, bite the bullet, and take it in to a local indy shop who does decent work at a reasonable price. No problem.

Wait...Big fucking problem! I can't get the throttle cables hooked back up because I can't free the up the covers because of the stripped screw. I wrestled with them for a while. Dropped the fucking little bitty brass bushings more times than I care to mention. Manipulated the throttle cable at the carb end AFTER losing a spacer washer off my SE air cleaner ( I have no idea where the little sonofabitch rolled).

Finally, I get the throttle side back together and look at my watch and it's now too fucking late to take it to the indy shop.

The whole day shot to hell!

'Bout the only good thing is, I didn't drop it.

Hope your day went better than mine.

[Husky23]

New bars huh 101?


I did that to my first ride - that Kawasaki. Fortunately though, I was lowering the bars – although that caused a problem of ‘extra’ cabling and what to do with it. The previous owner had “ape hangers” for bars and a 3 foot sissy bar mounted. Talk about hideous. Needless to say – all that had to go.

I really like the 05 Suzuki SV1000S, but I’m not digging the race-like low mounted clip-ons (I’m getting abit old for that). I may purchase, but NEED to know prior that I can safely replace the clip-ons with raised 1.5-2 inch raised ones. I’m thinking cabling could be the hang-up.

[Sailor]

"So I finally got my pullback bars, my braided stainless cables and my new MoCo grips and decide after reading all the posts on the Sportster board that it will take a little time but won't be all that difficult. After all, I have my service manual and lots of tools and the whole freakin' day to tinker away."

Somehow I just KNEW how the rest of the story was going to go. Sorta like when I tried to lay new linoleum in the bathroom. A "two hour job" that took 2 chunks of linoleum and all week end.

You have my sympathy 101. Break out another cold one.

[101ABN]

Well, my front end project is finally completed (with the help of an independent Harley wrencher I know). We finished it too late last night to get much riding in.

The new bars and grips will take a little getting used to and some fine adjustments may be needed but the difference is amazing. I don't feel like I'm reaching for the bars and the bike feels more nimble. The new fork springs are stiffer and while the damping effect isn't compromised, the front forks don't dive when I brake hard.

The braided stainless cables are way smoother than the stock ones and worth every penny of the cost, IMO.

Now, I'm just waiting for the dude in brown to deliver my Progressive 412's for the rear.

[Husky23]

admin said:

Well, my front end project is finally completed (with the help of an independent Harley wrencher I know). We finished it too late last night to get much riding in.

The new bars and grips will take a little getting used to and some fine adjustments may be needed but the difference is amazing. I don't feel like I'm reaching for the bars and the bike feels more nimble. The new fork springs are stiffer and while the damping effect isn't compromised, the front forks don't dive when I brake hard.

The braided stainless cables are way smoother than the stock ones and worth every penny of the cost, IMO.

Now, I'm just waiting for the dude in brown to deliver my Progressive 412's for the rear.

Well cool!! Hey post pics of your mods.

I just ordered a re-valved Ninja 636 shock to replace the stock unit on my ride. It doesn't do all too bad on smooth pavement but once you get aggressive and the road has bumps or ripples - it seriously lacks.

Soooo...I'm gunna cough up the cash - for safeties sake . This place will base set it for my wieght and style of riding, plus anodize it as I desire.



It should look like the above.

Then next is:

- Braided front brake lines.
- Performance (possibly EBC) brake pads.

After I tune up the rear, we'll see where the front suspension lacks.

Then a cosmetic enhancement:

- Color matched belly pan (still deciding what style).

The engine is plenty strong enough as it is, but at some point I'll:

- Do an airbox mod for better breathing.
- Add a Power Commander III programable electronic fuel control module.

Tis what I'm thinking. I just purchased a good sized magnetic tank bag and also a tiny one. And am looking for some soft saddle bags - for my sport tourer conversion.

[101ABN]

Braided lines and cables are awesome. I can't believe how much smoother my clutch and throttle function with the SS cables.

Pricey but worth it.

Tourmaster has a great line of nylon bags for sport bikes. I use their zip off faux leather saddlebags and have been very pleased with them.

I'll post some pics when I get the rear shocks on. UPS tracking says they'll be here tomorrow. Hope so because I have a trip down Hwy 1 through Big Sur planned for next weekend.

Oh Yeah!