How to Polish Brake Rotors on a Harley Davidson

There are a number of different ways to polish the brake rotors on a Harley. Brake rotors can be removed and sent to a shop to have them professionally done. Another method of polishing brake disks is to simply use silver polish or stainless steel cleaner on your rotors. You can even purchase chromed Harley brake rotors. For the Harley enthusiast who wants to go the extra mile to polish rotors without the expense, try wet sanding them and then using stainless steel polish to get them much closer to that chromed look.

Difficulty:

Moderate

Instructions

Things You'll Need

• Sandpaper (800 grade, 1000 grade, 1,500 grade)
• Electric drill with sandpaper attachment
• Electric drill wheel ball
• Water
• 12-by-12-inch plywood sheet
• Wood screws
• Stainless steel polish
• Chamois

1. • 1

     Remove the brake rotors from the motorcycle. Secure the rotors to the plywood with wood screws through the bolt holes. This will help keep the rotors from spinning while polishing.

   • 2

     Wet-sand the brake rotors. Start with the 800-grade sandpaper dipped in water. Rewet the sandpaper every 20 seconds or so. Switch to the higher grade sandpaper after a few minutes. The rotors should take about 10 minutes each.

   • 3

     Polish the brake rotors. Using the electric drill wheel ball, apply stainless-steel polish to the wheel ball. Polish the rotors on both sides. Remove the polish with a chamois.

   • 4

     Remove the rotors from the plywood. Replace the brake rotors on the Harley. Take bike for a test ride to make sure the rotors are remounted properly.

How to Modify Harley Davidson Mufflers

Mufflers on Harley Davidsons can be modified to fit your personality.

Changing the muffler on a Harley Davidson is a common way of personalizing your motorcycle. The job of a muffler is to reduce exhaust noise, although a major part of their function is also superficial. Increasing the size of your muffler will reduce the noise of the engine. Traditionally, holes were placed in the mufflers of Harley Davidsons to make them louder, although increasingly different colors and sizes of mufflers are allowing for a greater range of custom mufflers.

Difficulty:

Moderately Easy

Instructions

1. • 1

     Select whether you would like to replace your muffler, or simply customize the one that is currently on the bike. Slip fit mufflers can be bought in a range of colours and designs, and can be easily fit to your bike. Painting a muffler can be a more difficult process than buying a new muffler to fit.

   • 2

     Clean your muffler of grease and dirt using a paint thinner and a wire brush. Gently sand it to remove any excess raised areas or stubborn dirt. After you are happy with the finish, begin painting your muffler, using paint designed for high-temperature painting, such as barbecue paint, or specialty high-temperature paint. When you are happy with the painting, switch your bike on for 15 minutes, then off for 15 minutes, and then on for 15 minutes, which will dry the paint without overheating it.

   • 3

     Wrap the muffler with heat wrap in the section nearest the engine. This need only be the 6 inches nearest to the engine, which will be too hot even for the heat-resistant paint.

   • 4

     Buy a completely new muffler, if you decide to completely modify your Harley. These can be bought in a variety of motorcycle shops, and online, although you should be sure to cross-reference the specifications of your bike with those of the muffler to ensure that it fits.

   • 5

     Drill your muffler to make a deeper sound, which will make you safer on the road, as well as make your Harley sound more like a traditional Harley Davidson. Detach the entire exhaust system and using a 1/2 inch bit on a drill, drill through the baffles. Drill the holes as centrally as possible, or your muffler will 'whistle' not 'roar'. Reattach the exhaust and the muffler.

   • 6

     Fit a new muffler to your bike. If it is a slip-fit muffler, then you will need to loosen the clamps on your existing muffler and undo the lock nut underneath your bike's brake pedal. Slide off the old muffler, and reverse the process to attach the new one. Ensure that all of the nuts and clamps are tight.

How to Calibrate a Harley Speedometer

Calibrate your Harley speedometer to make sure you stay within the speed limit.

Harley-Davidson is a leading American motorcycle manufacturer; the company was founded in Milwaukee, Wisconsin, in the early 1900s. Known for it's low-seated design and it's boisterous rumble, the heavyweight motorcycle is designed for mid-speed cruising. The Harley-Davidson company has a large and enthusiastic consumer base, and is one of the best-selling motorcycle brands in the country.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Needle Nose Pliers
• Flathead Screwdriver
• Speedometer drive gear

• 1

  Test your speedometer by driving past laser radar-monitors with a visible readout. These monitors are often located in high-traffic residential neighborhoods or school districts. Determine if your speedometer reading is accurate or faulty.

• 2

  Visit or call your local Harley-Davidson dealer, and provide the representative with your motorcycle's model information. The company usually carries the the proper speedometer drive gears to calibrate your particular Harley

• 3

  Remove the speedometer's faceplate off with a flathead screwdriver. Remove the speedometer from the housing unit in the Harley dash. Use the needle nose pliers to remove the retaining clip. Take out the broken speedometer drive-gear, and set it aside.

• 4

  Place the new speedometer drive gear in the speedometer housing. Reinstall the retaining clip, place the speedometer housing-unit back in the Harley dash and reinstall the face plate

How to Install a Windshield on a Harley-Davidson

Installing a windshield will make riding more comfortable.

Many Harley-Davidson motorcycles come without windshields, but installing one will decrease your wind fatigue and keep bugs off your face. When choosing which windshield to install, you may purchase a Harley windshield installation kit designed for your specific model or use a different brand, as long as the specifications fit your particular motorcycle. In addition, it is best to choose a windshield made of a durable and distortion-resistant material, such as Lexan (polycarbonate) or Lucite (acrylic).

Difficulty:

Moderate

Instructions

Things You'll Need

• Windshield mounting kit
• Tape measure
• Drop cloths
• Screwdriver set

1. Preparation

   • 1

     Make sure your new windshield is mountable on either the headlight frame or handlebars of your Harley. Use a tape measure and write down specifications, such as headlight frame length and diameter and handlebar length and diameter. You can also look in your Harley's manual for the ideal windshield specifications or exact model number of your Harley.

   • 2

     Prevent scratches to your Harley's chrome and painted areas by placing drop cloths on the headlights and front fuel tank.

   • 3

     Remove the protective covering from your new windshield. Warming up the replacement windshield will make the material more pliant and easier to mount. To do this, place the windshield by a heating unit or above a stove.

   Installation

   • 1

     Decide whether you will attach your windshield to your Harley's lower spot lamp or handlebars. Although some universal windshields can be installed on your handlebars, it is more common to place the windshield on the spot lamp.

   • 2

     Place the windshield's bottom assembly jaws onto the rubber brushing grooves situated by the bracket of the spot lamp.

   • 3

     Connect both jaws of the top assembly piece to the grooves of the top rubber bushings.

   • 4

     Put your new windshield onto the rubber bushings.

   • 5

     Use a screwdriver and securely tighten the windshield mount to the Harley's front panel or headlamp.

Tips & Warnings

• Installing a windshield on your Harley will change its handling characteristics. Test the motorcycle after installation to become comfortable with the new handling.

How to Drill a Harley Muffler

Harley-Davidson motorcycles are known for their dependability, quality parts and workmanship, powerful engines and loud exhausts. However, most Harleys don't come standard with a loud, deep sounding exhaust. Oftentimes this is an aftermarket modification made by the owner to boost their noticeability on the road, making for a safer, less worrisome ride. Be noticed on your Harley by drilling out the stock baffles of your muffler.

Difficulty:

Moderate

Instructions

Things You'll Need

• Bike lift
• Metal cutting drill bit
• Hand-held drill
• Vise
• Shop rags
• Standard wrench set
• Rubber mallet

1. • 1

     Consult your owner's manual to determine where and how the exhaust pipes are held onto your specific model of Harley then set it on its kickstand or a motorcycle work lift.

   • 2

     Use the appropriate-sized wrenches to remove the exhaust system from the motorcycle. Be careful not to misplace any of the bolts or metal gaskets as they will be used to reattach the exhaust later.

   • 3

     Place the exhaust in a vise covered by shop rags or towels. Do not over-tighten the vise to avoid damaging the chrome finish on the pipes.

   • 4

     Attach an extension and a metal cutting drill bit (between 1/2 and 3/8 inch) to your hand-held drill. Insert the tip of the drill into the end of the muffler and drill through the first two baffles. Try to center the holes in the exhaust to prevent "whistling" when the exhaust is placed back on the bike.

   • 5

     Tap the mufflers with a rubber mallet or a fist to remove any remaining bits of metal from the drilled baffles. Reattach the exhaust to the bike. Make sure to tighten all bolts to the torque specifications found in your owner's manual or maintenance guide.

   • 6

     Fire up the bike and listen to the exhaust. It should be much louder and sound slightly deeper in tone. Take a quick test ride to show off your new, loud pipes.

How to Make the XL 883 Harley-Davidson Faster

Make the XL 883 Harley-Davidson Faster

The Harley-Davidson XL 883 Sportster is a fun, easy bike to ride, as well as a good commuter with high gas mileage. But sooner or later, the owner gets that itch for more speed. After all, the Sportster was Harley's original hot rod bike; even now, the fastest bike H-D makes is a Sportster. The XL 883 is no Hayabusa and never will be, but both Harley and the aftermarket produce products that can really wake up the Sportster.

Difficulty:

Challenging

Instructions

Things You'll Need

• Low-restriction air cleaner
• Low-restriction exhaust system
• Carburetor re-jet kit
• High-performance ignition module
• High-performance cam kit
• 1200 cylinders, pistons and rings

1. Basic Performance Upgrade

   • 1

     Install a low-restriction air cleaner. The original air cleaner doesn't breathe as well as it could, but Harley-Davidson sells a Screamin' Eagle filter kit that flows quite well, and aftermarket manufacturers also produce good filters.

   • 2

     Install a low-restriction exhaust system. You will probably want to do this anyway, because the factory system just doesn't let much of that classic Harley sound through. The low-budget option here is a set of Screamin' Eagle slip-in mufflers. They are engineered to lower exhaust backpressure when used with the original pipes.

   • 3

     Re-jet the carburetor. This is a must when you install air cleaners and exhaust systems; otherwise, the increased flow will result in a lean burn condition, which is bad for engine longevity. Harley sells a re-jet kit that includes all the parts and instructions for doing this.

   Intermediate Upgrade

   • 1

     Install a high-performance ignition module. The factory module works fine for general riding, but high-performance modules have adjustable advance curves that allow you to maximize the power of your particular setup. Here again, Harley-Davidson sells a Screamin' Eagle module. Crane also sells a Hi-4 ignition module for the Sportster.

   • 2

     Replace the stock ignition coils with high-performance coils for greater spark energy. This ensures a more complete burn of the intake charge.

   • 3

     Replace the stock cams with a high-performance set. Andrews is the top name here, with N-2 or N-3 cams for increased torque at all engine speeds, or N-4 cams for higher-speed performance.

   Upgrade to 1200

   • 1

     Remove the heads, pistons and cylinders.

   • 2

     Install 1200 pistons, cylinders and rings. These are available from Harley-Davidson, as well as aftermarket suppliers. This installation converts your 883 into a 1200.

   • 3

     Replace the heads. You can either re-use the 883 heads on your new 1200 cylinders, or upgrade to large-valve Sportster 1200, Buell or aftermarket heads.

How to Replace a Harley Sportster Drive Belt

Harley-Davidson belt drives are highly engineered systems that provide strong, quiet power to the rear wheel from the transmission drive sprocket. Built from super-strong fibers encased in polymer, the belt drive provides low maintenance and corrosion-proof service for thousands of miles. The belt construction eliminates the need for lubrication and frequent tension adjustments due to stretching, unlike the old chain drives.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Standard 3/8 and 1/2 inch socket set
• 3/8 inch ratchet
• 1/2 inch ratchet
• 1/2 inch torque wrench
• Bike jack (lift)
• Belt tension tool
• Rear axle alignment tool
• Short bungee cord
• C-clamp

1. • 1

     Lift the back of the bike with the bike jack. Remove the right footpeg mounting bracket. Remove the rear master cylinder and suspend it from a convenient point on the frame with the bungee. Remove the right side transmission cover plate. Remove the brake caliper from the left side of the swing arm and suspend it with a bungee.

   • 2

     Break the torque on the rear axle. Back off the axle adjusters evenly until the drive belt is slack. Remove the rear axle. Roll the tire forward slightly until the belt can be disengaged from the rear drive pulley. Remove the rear wheel from the bike. Remove the belt guard(s) from the swing arm. Remove the bottom shock mounting bolt from the swing arm and swing the shock up and clear of the swing arm. Remove the old belt from the transmission drive pulley.

   • 3

     Install the new belt onto the transmission drive pulley. Replace the lower shock mounting bolt and torque to factory specifications for your year of Sportster. Roll the rear wheel slightly forward of its mounting position and place the belt onto the pulley. Roll the wheel back and replace the wheel spacers and the rear axle. Tighten the axle finger tight.

   • 4

     Compress the rear brake caliper with the C-clamp and place it back onto the swing arm and the brake rotor. Re-install the caliper mounting bolts and torque to factory specifications. Tighten the axle adjusters evenly until most of the slack is removed from the drive belt.

   • 5

     Check the rear axle alignment with the axle alignment tool and align the axle if necessary. Replace the belt guard. Check belt tension with the tension tool. Push the bottom of the belt upwards until 15 pounds are indicated on the tool. Observe the deflection in the sight window of the belt guard. Refer to factory specifications for your model's belt tension deflection measurement and make corrections with the axle adjusters evenly until the appropriate deflection is attained. Re-check the axle alignment and make any axle corrections with the left-side axle adjuster only. Re-check belt tension once the axle is aligned.

   • 6

     Torque the axle nut to factory specifications. Re-install the transmission pulley cover, rear brake master cylinder and footpeg bracket. Pump up the rear brake with the brake pedal to insure proper feel and to allow the caliper to self-adjust back to its proper position.

Tips & Warnings

• Roll the bike with the engine off. Listen for a squeaky or rubbery noise at the belt pulleys. Audible squeaking indicates an out of alignment or insufficient belt deflection condition, and can lead to undue wear and early failure of the belt.