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Discussion Starter · #161 · (Edited)
I'm baaack! Been back a week, but couldn't bear the garage with 20's and 30's outside. Finally got out there today and got a few things done!

Started out simple - installed the button style backrest on the sissy bar.



I was afraid the medallion would have to come off, but the old pad just unscrewed after I removed the lower clip.



Next up, make the oil pump cover look like the original by adding a chain oiler adjusting screw and hose fitting. Drill and tap for 10-32 threads about 3/8" into the casting. This is plenty far from the oil passage, so it won't be functional or leak.



I used a NOS screw with the needle tip cut off, and also installed a piece of 3/16" rod for the hose. Should I soda blast it?



Someone gave me the bracket for the other end of the hose, so it'll look very stock except for the mess.
 
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Discussion Starter · #162 ·
I was going to tackle the main wiring harness, but between hard brittle insulation and some damage, I just ordered a new one from my local shop.

So then onto the handlebar controls:



Took them apart, and cleaned them up. The brake side is in decent shape,



but the clutch perch pivot is worn out. I'll have to find a replacement.



I like shiny things, so I polished the levers and pivots:



Does anyone know what is the correct black paint?
 
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Discussion Starter · #163 ·
One more question for the experts. It's impossible to find the correct brake hoses any more, they only sell the 83-up one piece hose now. Can anyone think of a reason I can't cut up the one piece assembly and double-flare the ends to use the original junction block? Is the tubing heavier wall than able to be flared?

 
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Discussion Starter · #165 ·
what is the "Clutch perch pivot" you refer to..??
This hole, which is now oval. Caused by lack of maintenance. You can see how dry the pivot pin is.
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Discussion Starter · #167 · (Edited)
Disassembly of the master cylinder was straight forward, including removing the sight glass:



The piston and seals looked like new because the previous owner had it rebuilt just before he sold it to me.



I drained some of the fluid into a small glass of water to confirm it was DOT5. DOT 3/4 dissolve in water.



I bought a Harbor Freight powder coating kit but they didn't have semi-gloss powder, so I'm on the hunt. I will soda blast everything and give them a good heating in the oven to drive out any oil or brake fluid the parts washer didn't remove. I saw that done on one of the shows on Motor Trend TV.


Then I took apart the calipers plus a spare I bought to replace one that had damage near the mounting bolt nut.



Unfortunately I bought the wrong side so I'll use the broken one.



The original paint looks like texture paint, so I won't powder coat them. I should still bake the old silicone brake fluid out of them so I don't get fish-eyes.

[edit: I just bought some semi-gloss powder for the controls and Harley fine texture powder for the calipers.]
 
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Discussion Starter · #168 ·
Thanks to a friend in Germany I have OEM clips for my handlebar wiring. Thanks, Troy

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Not much else going on now. Thursday I am going to soda blast my clutch and brake lever mounts and the four brake calipers I now own!

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Then I will practice powder coating with the worn out clutch mount so I can eventually do all of the parts.
 

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Discussion Starter · #169 ·
So it was a semi-successful day at my friend's garage. I was able to clean the brake m/c and clutch mount pretty well, but the calilpers must have been powder coated, they were impossible to get completely clean! The fitting is from the front brake hose assembly, I wonder if I should wire brush it to be shiny? I was able to get an NOS top hose and some good used lowers, so not cutting up the later hose assembly.

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Does anyone have advice on removing the coating from the calipers? Thanks
 
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Discussion Starter · #171 · (Edited)
I got a lot of suggestions for Aircraft paint or powder stripper, but since they stopped using methylene chloride, it isn't as effective. I will give them another go with wire wheels and sand blasting, then do a test with powder over what remains.

[edit: I found an old can of paint stripper that contains methylene chloride, so I will give that a try!]
 

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In case you get stuck on the powder coating, Eastwood is another source for equipment and supplies.
 

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Man this thread is awesome, and very informative. It's really gonna help me out when I go pick up the 83 FXR basket case I found. I have to have it, because that's my birth year, and I've always wanted an FXR, and an 83 shovelhead. I missed out on an 82 for $1200 that I was gonna redo also, because it was such a good price, but you snooze you lose. please keep it up, and if you have any pics of the disassembly please throw them into this thread to help out.
 

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Man this thread is awesome, and very informative. It's really gonna help me out when I go pick up the 83 FXR basket case I found. I have to have it, because that's my birth year, and I've always wanted an FXR, and an 83 shovelhead. I missed out on an 82 for $1200 that I was gonna redo also, because it was such a good price, but you snooze you lose. please keep it up, and if you have any pics of the disassembly please throw them into this thread to help out.
I wish I lived in your neighborhood , I bought my fxrs-sp '92 last month for 8000€ !!!
 

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Discussion Starter · #176 ·
Man this thread is awesome, and very informative. It's really gonna help me out when I go pick up the 83 FXR basket case I found. I have to have it, because that's my birth year, and I've always wanted an FXR, and an 83 shovelhead. I missed out on an 82 for $1200 that I was gonna redo also, because it was such a good price, but you snooze you lose. please keep it up, and if you have any pics of the disassembly please throw them into this thread to help out.
Nice to see you young guys getting into old bikes, and glad I can help. I have a lot of photos here if you want to look: FXR — Postimages. Disassembly was straight forward except for figuring out why the motor leaked so badly. Best advice is for you to bag and tag everything! Also, don't throw away anything until you have sorted out the replacement part on the bike, you may need it for reference. Good luck with your project, looking forward to pictures
 
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Nice to see you young guys getting into old bikes, and glad I can help. I have a lot of photos here if you want to look: FXR — Postimages. Disassembly was straight forward except for figuring out why the motor leaked so badly. Best advice is for you to bag and tag everything! Also, don't throw away anything until you have sorted out the replacement part on the bike, you may need it for reference. Good luck with your project, looking forward to pictures
I have done enough cars to know always bag, and label everything, and take lots of pics, I also don't ever throw parts away, even from tune ups in case something is bad. My only problem is the one I'm getting is a true basket case. I was asking for tear down photos for more bike porn LOL. Thanks for the link I will look through it all.
 

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I wish I lived in your neighborhood , I bought my fxrs-sp '92 last month for 8000€ !!!
It's not in my neighborhood I'm driving across the country to get it. I'm actully selling my reliable bike to fund the basket case.
 

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Discussion Starter · #179 ·
Success! 15 or so years ago I bought some paint stripper for a car restoration and still have most of a gallon. It still has the harsh chemical methylene chloride that you can't get any more. I soaked parts in it for 15-30 minutes:

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This stuff did a number on the powder coat and my glove! You can see the plastic came off in sheets.

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After a few hours of stripping and cleaning, I wound up with four clean calipers. I'll roughen the surface and get rid of little remnants with my friend's soda blaster tomorrow or Tuesday.

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Discussion Starter · #180 · (Edited)
The Made-in-USA V-Twin main wire harness came in and I installed it today. My local shop's prices are lower than online, too. First had to take care of a couple details.

First it didn't come with a neutral switch connector. Don't know why, but I was able to pry off the original one and crimp it on.





The socket connector for the rear fender wiring was white, but I had a black one and swapped out the wires.



Then I fed the wires thru the electrical panel with a new grommet and wired it all up on the bench. Here it is installed.



Unfortunately, when I was feeding the motor section around the frame and oil tank I accidentally yanked off the neutral connector! Yes I'm a dummy. They are available thru Harley so I'll be taking another trip soon.
 
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