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Old 28th October 2013, 10:54   #1
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Default My Harley Davidson XL1200N Nightster : Some mods & updates

Hello All.

Been away from a lot of things including riding for a while now. Just getting back on the saddle now.

Had never really done a proper introduction to my Nightster here on Team Bhp, and since it's coming up on it's 5th year, thought I would do a little write up. Wanted to share a few mods/upgrades I have done on my Sportster for interest of our growing HD population.

I imported this 08/08 manufactured Nightster from HD UAE via Chennai customs in 03/09 and have managed to put on little over 25000 kms by now.

Right around the time that I was getting my Diavel ready to ride, the Nightster's clutch had started giving out, and I had to park her for a while.

Had been planning to get the job done for a while, but circumstances did not allow it till couple of weeks ago.

Not to be the one to run down to the local Stealership for any help, started researching online, and narrowed down on Energy One clutches as replacement.

http://www.energyoneclutches.com/pro...&cat=13&page=1

Harley Clutches need a compression tool to release the clutch pack. There are several brands out there for replacement clutches with Barnett (http://www.barnettclutches.com/) being one of the more famous ones. But reading on XL forums, found that the Barnett advantage comes if you change the whole clutch pack, including the housing, which costs ~$800 before shipping, and then you need TWO special tools!! So, decided to go with the Energy One kit which you can buy with the tool for $209.

I did not get a chance to photograph the work this time, but there are plenty of youtube videos of Sportster clutch replacement, which is what I used to learn, and of course with my trusty mechanic K, was a piece of cake.

I would recommend a clutch upgrade to all Sportster owners. What a dramatic change!! The release is amazingly progressive and linear, and gear shifting has improved dramatically. Finding neutral is unbelievably easy now. The spring is now 15% heavier, but not that hard to get used to.

A word of advice for Sportster owners. If you feel your clutch is slipping, please replace immediately. The stock clutch comes with a plate that has brass rivets holding the edges, and these rivets break. Mine had broken and fell down just as I was pulling them out. If they break and dislodge while running, they can ruin your clutch basket, and you have to replace that as well. If you are planning on putting a lot of miles on your ride, I would recommend changing your clutch discs.

Since I was opening up the primary side, went ahead and changed the gaskets and seals from James Gaskets http://store.jamesgaskets.com/produc...roducts_id=717

Changed the clutch cable as well.
http://www.motionpro.com/motorcycle/partno/06-2389/

There was no need for either. Both the gasket and the clutch cable were in good shape, but what the heck, right?

The Pirelli Night Dragon tires had given me over 10k of great ride with fantastic grip and feel, and were due for replacement. Tried in vain to get the same, but had to settle for Michelin Scorcher 31's sourced from the local Stealer.

Since the tires were getting changed, went ahead and changed the Wheel Bearings as well. Should have done it long ago. What a difference it makes. My Harley, like most other Harleys used to have this nasty squeal when you roll to a stop. Also felt while pushing the bike around, mostly pushing backwards. Used to think that it was the brake disc rubbing, and have spent many hours checking trueness of the rotors, clearance with pads, etc., till I learned to live with it.

It aint a Hog if it dont squeal like a Pig, right? Apparently Not!!

Well, magic has happened, and with the new bearings, no more squeal. And I can really feel the lowered rolling resistance when I roll off the gas. $25 for a set!! Amazing!!
https://www.allballsracing.com/

Even though I had the battery disconnected while the bike was parked, inspite of charging it for two days before I started the work, it just didnt have enough juice to give me confidence. Got tired of lead acid battery headaches and ordered Shorai Lithium batteries for both the Harley and the CB. Now all my bikes are "Unleaded"
http://shoraipower.com/

For those interested, my bike also has the following mods previously done:
- Intiminators. Inertia Active front suspension upgrade. For details, please see:http://www.team-bhp.com/forum/superb...iminators.html (Harley Sportster Front suspension upgrade - RICOR Intiminators)
- Vibranators in the Handle Bars
- Progressive 440 rear suspension
- Balancing beads in my tires. For details, please see:
http://www.team-bhp.com/forum/superb...superbike.html (Wheel Balancing dynamically on my Superbike)

The best part of a Harley is how a few small things like this dramatically changes the bike. I now feel like I have a NEW 5 year old bike!!

Some pictures from a visit to the local Biker's Cafe.
My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1632-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1681-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1651-848x1280.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1660-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1664-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1671-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1677-1280x848.jpg

My Harley Davidson XL1200N Nightster : Some mods & updates-dsc_1678-848x1280.jpg

Last edited by gthang : 28th October 2013 at 10:59. Reason: Typo
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Old 29th October 2013, 16:25   #2
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Default Re: My Harley Davidson XL1200N Nightster : Some mods & updates

Thread moved from the Assembly Line (The "Assembly Line" Forum section) to Motorcycles. Thanks for sharing!
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Old 29th October 2013, 17:41   #3
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Default Re: My Harley Davidson XL1200N Nightster : Some mods & updates

Wow hard to believe that the bike is 5 years old. Very well kept and maintained Sir.
Are there any difference between the UAE Model & Indian model?
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Old 29th October 2013, 18:55   #4
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Default Re: My Harley Davidson XL1200N Nightster : Some mods & updates

That's one beautiful bike!! I really like your saddle. Do share details for the same.
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Old 29th October 2013, 19:03   #5
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Default Re: My Harley Davidson XL1200N Nightster : Some mods & updates

Quote:
Originally Posted by ku69rd View Post
Wow hard to believe that the bike is 5 years old. Very well kept and maintained Sir.
Are there any difference between the UAE Model & Indian model?
Thanks. It's also got over 25,000 km on it. I am a little paranoid about maintaining my bikes. Guess it shows

Not supposed to be any different. My bike is also Euro spec as the CBU Indian bikes were. Only thing is that they discontinued the Orange color in 2010 and went to Red. So, my Nightster might be the only Orange/Black one in the country.

Quote:
Originally Posted by dkaile View Post
That's one beautiful bike!! I really like your saddle. Do share details for the same.
Thanks dkaile. The saddle is my Friend's seat from his Superlow which I am swapping for a while. It's a Mustang Seat. I believe it's this one:

http://www.mustangseats.com/Product/...45-gallon-tank

Cheers

Ride Safe
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