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Old 10-22-2008, 01:12 PM   #1 (permalink)
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FXR Teardown and rebuild... Oh Geeezzz

88' FXRS - The years have not been good to my 88', the frame paint is chipping, tins are weathered, and no matter how much I clean the bike I cannot touch it without getting dirty. After pinning my powder coater down to painting my entire bike for next to free, I have decided to tear this puppy down in December and sandblast/paint the frame and tins the beautiful matte black... yes I am considering painting the frame matte black as well but not completely convinced, opinions and pictures would also be helpful for this..

Question:
Any tips on tearing this bike down would be appreciated, I am a novice on motorcycle mechanics.

Additionally, tools that I may not think about needing until 1 AM when everything's closed? I do have the parts manual from HD...

My wrench has encouraged me to do as much work myself as I can in the spirit of education and has assured me that he will be there to help with the tricky stuff.

All help and suggestions would be awesome.
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Old 10-22-2008, 04:05 PM   #2 (permalink)
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I know you said you had the parts manual, but better get the Service manual too. Read through it before ya start a bit. First thing you are gonna need if you dont have already is a Jack/lift of some kind to support the bike by the frame while taking off the front end/back tire. The higher you can get it the easier it is to work on the rest too.
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Old 10-22-2008, 04:21 PM   #3 (permalink)
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Label some freezer bags for small parts and what assembly they go with. Digital camera will help also.
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Old 10-23-2008, 12:53 PM   #4 (permalink)
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Don't be worried-GO FOR IT! It's exciting to really get into your own bike-the pride you will feel when you ride it after YOU did most of the work is irreplacable!
Couple more things-make sure you have a place to work without distractions and that has plenty of room to keep everything together. I try to keep all the bike pieces in sections-wheel parts front, rear-front end-rear- engine etc...
Finally-wiring. when you disconnect your wiring harness at each end point wrap tape around each end and mark exactly where it came from.
Good Luck and HAVE FUN!
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Old 10-23-2008, 03:11 PM   #5 (permalink)
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I got a bike lift for $60 from Craigslist, but it is the scissor lift platform type. Though extremely sweet i do see the point that I will need something to hold frame up while removing tires.

I have the service manual, Harley Davidson edition, I have heard thought that the Clymer's manual with illustrations may be superior, but i think that I should be good with the 300+ page book that I currently have.

I was thinking about rewiring the bike with some more "updated' wiring, any suggestions? Also any other suggested mods?
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Old 10-24-2008, 08:39 AM   #6 (permalink)
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Quote:
Originally Posted by ocbishop View Post
I got a bike lift for $60 from Craigslist, but it is the scissor lift platform type. Though extremely sweet i do see the point that I will need something to hold frame up while removing tires.

I have the service manual, Harley Davidson edition, I have heard thought that the Clymer's manual with illustrations may be superior, but i think that I should be good with the 300+ page book that I currently have.

I was thinking about rewiring the bike with some more "updated' wiring, any suggestions? Also any other suggested mods?
I haveClymer for FXR and working on bike with it is pleasure - pictres, detailed info but it also has some mistakes (like saying "left thread on comensator sprocket" ).

Changing wiring is IMHO waste of time - stock one (if it`s good) is simple and work great (at least on my bike).

Other mods? Depends what is YOUR plan and how much dod you want to spend. If the $ is no problem I would look for some engine mods, suspension & brakes upgrade.
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Old 10-24-2008, 07:07 PM   #7 (permalink)
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Don Camillo, how's your bike doing?

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Old 10-24-2008, 07:58 PM   #8 (permalink)
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IMO the lift is not needed. The HD factory service manual is a MUST. A digital camera can be invaluable. Take a picture of EVERYTHING before, during and after you take it apart. As you take pictures, you can review them in reverse order when you put it back together so you know order in which it was taken apart. You can also also use the zip locks as mentioned and when you label them, add a number as you go. Number low to hi during disassembly and install hi to low during reassembly.

Why no lift is really required..... Here is rough disassembly order. Remove the tank, seat and fenders. Remove the foot controls, rear master, clutch perch from bars, side covers etc. Strip miscellaneous parts etc. Remove oil tank, oil lines, carb, starter, primary etc. Remove engine, leave tranny. Basically you will be left with a rolling chassis and a tranny. Pull the front end as an assembly, if you can. Then pull the rear tire. Leaving a frame, rear swing arm and tranny. This is where the fun begins. If you have never had the pivot bolt out it will likely be a real challenge. Here is a thread that covers the basics ... http://www.v-twinforum.com/forums/wh...m-problem.html

The wiring harness ... The old wiring harnesses have have multiple problems. Most have been molested in some way. The connectors oxidize and splay. The terminals get corroded and it usually is a task keeping all the stuff working. When I rebuild a bike I like to use a thunderheart wiring harness. You might consider it. Here is a thread about them ... http://www.v-twinforum.com/forums/el...t-harness.html
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