My '09 Harley XR1200 build thread

Discussion in 'Road Warriors' started by The Virginian, Nov 19, 2016.

  1. Mudclod

    Mudclod Mojo Moto

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    [​IMG]


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  2. The Virginian

    The Virginian Been here awhile

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    On post #86 I installed a LED headlight which is HUGE improvement on visibility at nighttime. I totally agree that it needs a little larger headlight and maybe eventually I'll get to that. I have so many items to address I guess I'm more focused on just getting it 100% road worthy and performing up to it's capabilities. Thanks you for the kind remarks on my build thread and glad you're enjoying it.

    Eric
  3. The Virginian

    The Virginian Been here awhile

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    Just awesome Mudclod! You headlight looks great!
  4. mississippimadman

    mississippimadman Been here awhile

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    What wheels do you have
  5. Mudclod

    Mudclod Mojo Moto

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    It's not mine, I just knew of a bike with a large headlight that @blipco had mentioned. I once saw a number plate headlight combo that I really liked but it was rather pricey. It might have been from Storz.
  6. blipco

    blipco Adventurer

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    Here's a little off topic info.
    I was looking at a 2008 Ducati Monster S2R that a friend was selling. They had problems with the plastic tanks as well. Apparently, Acerbis, who makes the tank for them and Harley as well as others didn't account for the ethanol in the gas. And that's where I learned about the XR tank problem.

    Anywho, Ducati had a safety recall due to if the tank expanded it would contact the hand controls during hard turns during full lock parking lot maneuvers. You are only allowed one tank to be recalled.

    So what they did, instead of improving the plastic material of the tank, they made the replacement tank 1/2 gallon smaller so that when it expanded again it wouldn't hit the controls. Dumb fix IMO.

    I didn't buy the bike only because I lost interest. It was mint.
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  7. Alexander B

    Alexander B Been here awhile

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    Although many like to blame ethanol in gas for every and any bike related issue they encounter, it is probably incorrect in this case. I remember reading that people owning the XR1200 in countries where there is NO ethanol mixed in the gas, STILL get the swelling problem.
    Typically, ethanol is also inert in combination with many common plastics.
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  8. Alexander B

    Alexander B Been here awhile

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    Great build thread, by the way!
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  9. The Virginian

    The Virginian Been here awhile

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    Thanks for contributing to the discussion.

    It very may well be, luckily this bike doesn't seem to be affected.


    I hadn't read this and thank you for the insite.
    Thanks for stopping by and commenting.
  10. The Virginian

    The Virginian Been here awhile

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    While I'm waiting on the body shop for the seat pan, I need top think about a tidy tail to tuck under the Free Spirits solo cowl seat. I welcome any thoughts on this front. I'm indecisive whether I'll stick with the OEM LED style rear brake light or go with a low profile LED lamp.

    Here's a few I've been looking at:
    http://www.rg-racing.com/browsebike/Harley_Davidson/XR1200/2012/LP0090BK/

    Evotech tidy tail: Discontinued

    http://www.storzperf.com/catalog/page7.html (dosen't appear to have a plate light required by VA)

    http://www.twinmotorcycles.nl/websh...R1200_Taillight_with_licenceplate_support_IT_ (no light on plate, Euro plate holder but can be modified)

    Or last chance I can fab one out of Rizoma

    https://www.motostrano.com/Rizoma-License-Plate-Light-Kit-p/ee091b.htm
  11. The Virginian

    The Virginian Been here awhile

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    A small update as I'm nearing the end of this build. I have worked my buns off on this build over winter and I'm ready to twist some throttle.

    I purchased some anti-seize for the new stainless steel bolts that will hold on the rear brake line bracket. I've never really used this stuff before...
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    A dab on each bolt and cinched her down to spec torques. Note that this area has been detailed now and waxed the frame in this area as it was super grimy before. It's getting there slowly but surely.
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    Mounted up the new banjo bolts.
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    Topped her off with some fresh DOT 4 brake fluid.
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    Started the bleeding process.
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    It started pissing brake fluid out of the sender switch area. Gah! So I'll have to dismantle that and clean the switch up again and apply a healthier dose of Locktite 565...

    (more to come)
  12. The Virginian

    The Virginian Been here awhile

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    Well today's update is an exciting one! She's coming together and looking mighty sharp if I do say so myself. :jkam

    Installed and setup the Öhlins! Woot woot! I followed Howard's instructions to the letter. I'm still waiting on the shock nut I lost a while back as it's on backorder. So no test rides over one lousy bolt. Grrr.... :p3rry

    The shocks came with a sleeve to convert the mounting hole from metric to standard. Pretty slick!
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    Installed.
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    So I'm buttoning up the shock and getting ready to tackle the rear brake line that was weeping I get a text....
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    Hot damn! :happay:smile6:bow:bow:bow :bowMy paint work is done and he texted me some pics.
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    (more to come)
  13. The Virginian

    The Virginian Been here awhile

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    So I skedaddle over to the bodyshop and pick them up. I'm super interested to see how the gash came out on the tank skin. Magnificent job! :0-0

    Before.
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    After
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    The number plate solo tail is absolutely stunning. The Mirage Orange Pearl in direct sunlight just dances.
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    Here's a couple for the overall effect put together as a mock at this point in time.
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    That's it for today and what an exciting day it was for me. Steel braided front brake lines have been ordered and I need to advocate or defecate :topes on the tidy tail question. Once the brakes and tidy tail are done it's time to try her out and get her dialed in. :bandit

    Thanks all for reading! :beer

    (more to come)
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  14. blipco

    blipco Adventurer

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    It's a stunner.
    I've seen but one of these on the road and it was all stock yet it catches your eye. Yours is gonna get a lot of attention.
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  15. Florida Lime

    Florida Lime Long timer

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    I had to wait until I was at home to see the pictures - looks GREAT ! :thumb
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  16. Coltrane

    Coltrane Adventurer

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    She looks awesome! Can't wait to hear about the road test :-)


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  17. RobN.

    RobN. A little Odd

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    on the tidy tail question

    I put a Custom Dynamics Insert in the brake/tail of my Roadster. It is BRIGHT. I really notice the difference if I begin flashing the brake light as I come to a stop. I can see the person noticing me, and backing off. Lot's of tailgators around here.
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  18. Alexander B

    Alexander B Been here awhile

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    Looks great!
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  19. Badge320

    Badge320 Wild Hog No. 3

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    Nice paint work.

    Are those new shocks longer than stock..?

    If so....you may have a clearance issue with the exhaust and swing arm. I'm racing an XR 1200 with 2" over Race Tech shocks on the rear. The V and H exhaust has contacted and wore a groove into the swing arm. Common issue. I shimmed out the exhaust just a tiny bit to fix the issue. Now. when I sit on the bike there is enough clerance. I know you're running a different exhaust but you still may want to check.
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  20. The Virginian

    The Virginian Been here awhile

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    Very kind of you to say. Mine's no beauty queen but she's scrubbing up.

    Thank you FL! I appreciate you continuing to enjoy my thread.

    I'll post some detailed thoughts when I get her on the road. I'll probably post a short video as well. ;)

    Thanks for the advise, I'll be sure to check them out.

    Thanks!

    No, I went with standard length. After I spoke with Howard on the phone that I posted about earlier, it was an easy decision for me to to just stick with the standard length. I appreciate the heads up on the clearance issue and I'll be sure to triple check my work before I test it out.