2001 xl883h mid-glide front end.
#21
From a stock mid glide front end:
Top tree
Bottom tree (with stem)
Tubes (2)
Compression springs (2)
Rebound springs (2)
Damper tubes and expander seals (2 each)
Slider bushings (2)
Tube Bushings (2)
Seals (2)
Seals retainer clips (2)
Seal seating washers (2)
Damper tube locator dowels (2)
Damper bolts and copper sealing washers (2 each)
Fork caps (2)
Fork cap o-rings (2)
Fork oil (2 pints)
Dust seals (2)
Decorative seal covers (2)
Right slider
Left slider
Axle clamp bolt, nut, washer, lock-washer
Axle, nut, and washer
Pinch bolts for trees (4)
Pinch bolt for stem
Stem adjustment bolt and washer
Stem bearings, upper and lower dust shield
Other recycled parts I used:
21" wide glide wheel hub set for 3/4" bearings (requires machining)
16" rim, spokes and nipples
Aluminum 25mm wheel spacers (requires machining)
Hub spacer for 25mm axle (requires machining)
New parts required:
Wheel bearings (25mm)
16" tire, tube, and rim strip
Parts required for brake:
Stock disc and bolts (2001 xl)
Stock brake caliper (2001 xl)
Stock brake caliper bolts (2001 xl)
Other items to mention are that I had to measure to find the wheel offset when lacing it, so that the tire was centered between the forks. Wheel spacers were machined to center the disc in the caliper body. I also had to bend the fork lock bracket welded to the frame down slightly. The headlight 'eyebrow' had to be modified slightly to fit under the top tree. Could be avoided if you go with a lower tree mount, as the lower tree is already drilled for it. Factor in a different headlight bucket and bracket though. The stop doesn't contact the tree stand-offs as much as I'd like so I'll probably take it apart and machine some excess material off the lower tree where the bearing sits. I'll be sure to take pictures.
All in all I think I have about $175 in the front end parts. $180 for the tire, tube, rim-strip. $70 in tooling. Not to mention a bunch of time making it work.
Last edited by pFlarey; 02-02-2016 at 11:58 PM.
#25
#27
Ok so, the internal throttle is installed. I drilled the right side riser bolt to route the cable. The cable itself is made up of two separate throttle cables. I needed to include an adjuster, and wanted to hide it. Ended up under the fuel tank. I think it turned out better than expected.
#30