1999 FLSTC Project Log
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Road Warrior
Joined: Feb 2012
Posts: 1,879
Likes: 10
From: Jacksonville
1999 FLSTC Project Log
I'm a noob when it comes to this sorta thing. I bought a 1999 FLSTC to have something to tinker with and learn a few things. It's my first project bike, so I figured I'd post a log for anyone else who wants to do something like this. I'm trying to do this on the cheap, and hopefully sell it when I'm done for a small profit, or at least break even. Hell, I might just keep it and see if I can break 100K.
The Bike:
1999 FLSTC. 75K miles. Lots of patina. I got it pretty cheap though. The paint is decent and it runs, so I can always ride it and it won't be just a garage stain. I'll post pics soon.
Completed:
1. Changed oil, oil filter and cleaned air filter. This was my first time doing this. It was messy. The more I do it the less mess I hope to make.
2. Fixed neutral indicator. The leads completely fell off the neutral indicator on the engine. They were hard to get at and one of them wasn't tight enough to stay on. I used needle nose to crimp it just a little and it seems good now.
3. Fixed Speedo. This required a new deutch connector to be put on. My boss had a spare one. Before, the d02, d06 and d10 codes were "set", but now the d02 code is still "set" but everything works.
4. Fixed horn. Required an unplug / replug
5. Lubed clutch, brake and throttle cables. Had some goo in a needle I got on the internet. I bought it for my friend's clutch but had *plenty* of extra.
6. Replaced jiffy stand spring. Tried several times pulling it with pliers which I couldn't do. Ended up using a screwdriver.
7. WD-40 squeaky spots, like passenger footboards. Self explanatory
8. Fix console lights. This just required removing and reinserting the bulbs. There is one bulb that I think is dead, so I'll get a new one.
9. Replaced console insert. To me, this is the first thing I see when it's all roached out. I also ordered a new tank bib.
TODO:
A lot.
1. The shifter spline seems loose in the housing, allowing it to pivot up and down perpendicular to the bike. The service manual doesn't have anything about how to assemble it, but I found an explosion diagram on the internet. I got replacement parts from an online harley parts store, but they were supposed to be x2, but they were x1.
2. The brakes seem really weak. I don't know if it's just evo brakes or they need work. I bought some shoes and pads and will research how to replace the fluid.
3. Need to replace primary and transmission fluid.
4. Holy **** this thing is filthy. I'm a slob and it's filthy to me. There is black dust everywhere and sand all over. There is grease / oil everywhere with sand in it. Even under the dash is amazingly dirty.
5. Fix the rust. There is pitting and rust everywhere. I will replace the parts that are unfixable, but will try to scrub and wax the smaller rust spots with a ball of aluminum foil and wax. The foil works ok. Wife bought be steel wool which is supposed to work better, but it had soap in it.
6. Shifting seems harder than it should be. It gets much easier from 2-3, then 3-4+. 1st to 2nd is a bear. I don't know how much of this is #1, but I'm hoping it isn't a transmission issue.
7. Right front blinker blinks, but doesn't illuminate when not blinking.
8. Replace the hand controls and housing. I'll probably keep the electrical as is. The buttons don't have any more paint and the housings are pretty roached.
More to come.
The Bike:
1999 FLSTC. 75K miles. Lots of patina. I got it pretty cheap though. The paint is decent and it runs, so I can always ride it and it won't be just a garage stain. I'll post pics soon.
Completed:
1. Changed oil, oil filter and cleaned air filter. This was my first time doing this. It was messy. The more I do it the less mess I hope to make.
2. Fixed neutral indicator. The leads completely fell off the neutral indicator on the engine. They were hard to get at and one of them wasn't tight enough to stay on. I used needle nose to crimp it just a little and it seems good now.
3. Fixed Speedo. This required a new deutch connector to be put on. My boss had a spare one. Before, the d02, d06 and d10 codes were "set", but now the d02 code is still "set" but everything works.
4. Fixed horn. Required an unplug / replug
5. Lubed clutch, brake and throttle cables. Had some goo in a needle I got on the internet. I bought it for my friend's clutch but had *plenty* of extra.
6. Replaced jiffy stand spring. Tried several times pulling it with pliers which I couldn't do. Ended up using a screwdriver.
7. WD-40 squeaky spots, like passenger footboards. Self explanatory
8. Fix console lights. This just required removing and reinserting the bulbs. There is one bulb that I think is dead, so I'll get a new one.
9. Replaced console insert. To me, this is the first thing I see when it's all roached out. I also ordered a new tank bib.
TODO:
A lot.
1. The shifter spline seems loose in the housing, allowing it to pivot up and down perpendicular to the bike. The service manual doesn't have anything about how to assemble it, but I found an explosion diagram on the internet. I got replacement parts from an online harley parts store, but they were supposed to be x2, but they were x1.
2. The brakes seem really weak. I don't know if it's just evo brakes or they need work. I bought some shoes and pads and will research how to replace the fluid.
3. Need to replace primary and transmission fluid.
4. Holy **** this thing is filthy. I'm a slob and it's filthy to me. There is black dust everywhere and sand all over. There is grease / oil everywhere with sand in it. Even under the dash is amazingly dirty.
5. Fix the rust. There is pitting and rust everywhere. I will replace the parts that are unfixable, but will try to scrub and wax the smaller rust spots with a ball of aluminum foil and wax. The foil works ok. Wife bought be steel wool which is supposed to work better, but it had soap in it.
6. Shifting seems harder than it should be. It gets much easier from 2-3, then 3-4+. 1st to 2nd is a bear. I don't know how much of this is #1, but I'm hoping it isn't a transmission issue.
7. Right front blinker blinks, but doesn't illuminate when not blinking.
8. Replace the hand controls and housing. I'll probably keep the electrical as is. The buttons don't have any more paint and the housings are pretty roached.
More to come.
Last edited by Clubber; Nov 27, 2014 at 09:13 AM.
Dirt don't hurt
Joined: Jan 2011
Posts: 21,062
Likes: 4,547
From: Haslet Texas
I'm a noob when it comes to this sorta thing. I bought a 1999 FLSTC to have something to tinker with and learn a few things. It's my first project bike, so I figured I'd post a log for anyone else who wants to do something like this. I'm trying to do this on the cheap, and hopefully sell it when I'm done for a small profit, or at least break even. Hell, I might just keep it and see if I can break 100K.
The Bike:
1999 FLSTC. 75K miles. Lots of patina. I got it pretty cheap though. The paint is decent and it runs, so I can always ride it and it won't be just a garage stain. I'll post pics soon.
Completed:
1. Changed oil, oil filter and cleaned air filter. This was my first time doing this. It was messy. The more I do it the less mess I hope to make.
2. Fixed neutral indicator. The leads completely fell off the neutral indicator on the engine. They were hard to get at and one of them wasn't tight enough to stay on. I used needle nose to crimp it just a little and it seems good now.
3. Fixed Speedo. This required a new deutch connector to be put on. My boss had a spare one. Before, the d02, d06 and d10 codes were "set", but now the d02 code is still "set" but everything works.
4. Fixed horn. Required an unplug / replug
5. Lubed clutch, brake and throttle cables. Had some goo in a needle I got on the internet. I bought it for my friend's clutch but had *plenty* of extra.
6. Replaced jiffy stand spring. Tried several times pulling it with pliers which I couldn't do. Ended up using a screwdriver.
7. WD-40 squeaky spots, like passenger footboards. Self explanatory
8. Fix console lights. This just required removing and reinserting the bulbs. There is one bulb that I think is dead, so I'll get a new one.
9. Replaced console insert. To me, this is the first thing I see when it's all roached out. I also ordered a new tank bib.
TODO:
A lot.
1. The shifter spline seems loose in the housing, allowing it to pivot up and down perpendicular to the bike. The service manual doesn't have anything about how to assemble it, but I found an explosion diagram on the internet. I got replacement parts from an online harley parts store, but they were supposed to be x2, but they were x1.
You might try a better lever http://betterlever.com/
2. The brakes seem really weak. I don't know if it's just evo brakes or they need work. I bought some shoes and pads and will research how to replace the fluid.
It is EVO brakes (inherently weak).
The front is easy as gravity will drain it for you the rear I use a vacuum pump I got at Harbor freight for $20 (it makes it a lot easier).
3. Need to replace primary and transmission fluid.
I got a drain tray from Harley that is big enough to catch all the fluid when opening the primary (think bigger than a turkey baster tray)
4. Holy **** this thing is filthy. I'm a slob and it's filthy to me. There is black dust everywhere and sand all over. There is grease / oil everywhere with sand in it. Even under the dash is amazingly dirty.
Talk to traildog.
He is our resident cleaning expert.
5. Fix the rust. There is pitting and rust everywhere. I will replace the parts that are unfixable, but will try to scrub and wax the smaller rust spots with a ball of aluminum foil and wax. The foil works ok. Wife bought be steel wool which is supposed to work better, but it had soap in it.
6. Shifting seems harder than it should be. It gets much easier from 2-3, then 3-4+. 1st to 2nd is a bear. I don't know how much of this is #1, but I'm hoping it isn't a transmission issue.
The better leaver will probably help with this.
7. Right front blinker blinks, but doesn't illuminate when not blinking.
Sounds like it needs a new bulb.
8. Replace the hand controls and housing. I'll probably keep the electrical as is. The buttons don't have any more paint and the housings are pretty roached.
More to come.
The Bike:
1999 FLSTC. 75K miles. Lots of patina. I got it pretty cheap though. The paint is decent and it runs, so I can always ride it and it won't be just a garage stain. I'll post pics soon.
Completed:
1. Changed oil, oil filter and cleaned air filter. This was my first time doing this. It was messy. The more I do it the less mess I hope to make.
2. Fixed neutral indicator. The leads completely fell off the neutral indicator on the engine. They were hard to get at and one of them wasn't tight enough to stay on. I used needle nose to crimp it just a little and it seems good now.
3. Fixed Speedo. This required a new deutch connector to be put on. My boss had a spare one. Before, the d02, d06 and d10 codes were "set", but now the d02 code is still "set" but everything works.
4. Fixed horn. Required an unplug / replug
5. Lubed clutch, brake and throttle cables. Had some goo in a needle I got on the internet. I bought it for my friend's clutch but had *plenty* of extra.
6. Replaced jiffy stand spring. Tried several times pulling it with pliers which I couldn't do. Ended up using a screwdriver.
7. WD-40 squeaky spots, like passenger footboards. Self explanatory
8. Fix console lights. This just required removing and reinserting the bulbs. There is one bulb that I think is dead, so I'll get a new one.
9. Replaced console insert. To me, this is the first thing I see when it's all roached out. I also ordered a new tank bib.
TODO:
A lot.
1. The shifter spline seems loose in the housing, allowing it to pivot up and down perpendicular to the bike. The service manual doesn't have anything about how to assemble it, but I found an explosion diagram on the internet. I got replacement parts from an online harley parts store, but they were supposed to be x2, but they were x1.
You might try a better lever http://betterlever.com/
2. The brakes seem really weak. I don't know if it's just evo brakes or they need work. I bought some shoes and pads and will research how to replace the fluid.
It is EVO brakes (inherently weak).
The front is easy as gravity will drain it for you the rear I use a vacuum pump I got at Harbor freight for $20 (it makes it a lot easier).
3. Need to replace primary and transmission fluid.
I got a drain tray from Harley that is big enough to catch all the fluid when opening the primary (think bigger than a turkey baster tray)
4. Holy **** this thing is filthy. I'm a slob and it's filthy to me. There is black dust everywhere and sand all over. There is grease / oil everywhere with sand in it. Even under the dash is amazingly dirty.
Talk to traildog.
He is our resident cleaning expert.
5. Fix the rust. There is pitting and rust everywhere. I will replace the parts that are unfixable, but will try to scrub and wax the smaller rust spots with a ball of aluminum foil and wax. The foil works ok. Wife bought be steel wool which is supposed to work better, but it had soap in it.
6. Shifting seems harder than it should be. It gets much easier from 2-3, then 3-4+. 1st to 2nd is a bear. I don't know how much of this is #1, but I'm hoping it isn't a transmission issue.
The better leaver will probably help with this.
7. Right front blinker blinks, but doesn't illuminate when not blinking.
Sounds like it needs a new bulb.
8. Replace the hand controls and housing. I'll probably keep the electrical as is. The buttons don't have any more paint and the housings are pretty roached.
More to come.
Stellar HDF Member
Joined: Jul 2011
Posts: 2,583
Likes: 115
From: Boston, MA
Happy Thanksgiving Clubber, all
Sorry op but I can't resist... I cannot wait until February when you're all done with your bullet points and have about a thousand miles and you start a new thread: "What can, how can I get the Evo to at least keep up with the flhx?"
Just busting your chops but wait 'til you're done and the bug bites you in the ***. It's very addicting!
Tom
Sorry op but I can't resist... I cannot wait until February when you're all done with your bullet points and have about a thousand miles and you start a new thread: "What can, how can I get the Evo to at least keep up with the flhx?"
Just busting your chops but wait 'til you're done and the bug bites you in the ***. It's very addicting!
Tom
Seasoned HDF Member
Joined: Nov 2009
Posts: 15,705
Likes: 22,717
From: Farmington ,MS
Put on jack or have someone sit on it and hold it up...remove stop on top of stand...swing stand around...put spring on...swing back and reinstall stop...saves blood sometimes.
Cruiser
Joined: Nov 2014
Posts: 108
Likes: 1
From: Astoria, OR
As suggested a vacuum pump to get all the old brake fluid out. Clean, clean and clean the reservoirs out them fill with some new DOT-5. Use the vacuum pump to move the new fluid through the system a bit, then make one more manual brake bleed keep the fluid in the reservoir. Works very well. Just re-did both front and back brakes including new pads and rotors. The old front rotor was warped a bit. I've heard new brake lines will help also, but for my riding, the brakes work very well.
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Ultimate HDF Member
Joined: May 2006
Posts: 6,590
Likes: 444
From: Ohio
It's not necessarily your riding style it's the other idiots out there as well as deer, dogs, alligators, etc. Brakes are never "good enough". Good pads and braided lines do wonders for any brakes with not much money.
Outstanding HDF Member
Joined: Nov 2013
Posts: 2,358
Likes: 34
For the rust on any part even chrome, use crumpled or balled aluminum foil and diet coke. It does an amazing job at removing the rust with almost no effort. It won't hurt the chrome either you can go right over it. I had rust everywhere.
Seasoned HDF Member
Joined: Mar 2010
Posts: 21,003
Likes: 7,537
From: Poolville
brake master cylinder
Don't know how many of you guys or gals ran into this but on my 98 the OEM foot master cylinder cover is made out of a real cheap pot metal that actually warped and let moisture in contaminating my rear brake system (happened more than once) which required a complete clean n bleed. You can straighten it and put back on but would like to see an upgrade without buying a complete master cylinder. Any one else run into this?