Chubby 513 project
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Outstanding HDF Member
Joined: Mar 2005
Posts: 2,007
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From: Vancouver, B.C.
Chubby 513 project
Tried to post 1st day progress yesterday on my weekend project but the site went down just as I finished previewing my post.
Now I'm at the end of Day 2. Things are not going well in my eyes.
Yesterday I was able to tear everything apart and get the forks modified, the RaceTech Gold valves and springs installed, and get the front end back together again. I took my time, but still had 11 hours into it.
Today I put in another 10 hours. In order to access the clutch release cover I had to remove my entire exhaust system. (that was fun...NOT) Turns out I have the same problem as UGGA. The threads on the end of the Barnett clutch cable do not match those in the cover...and I don't know what the thread is. I have gone through all the taps I have, and I have two full sets at hand. The thread on the cable is finer than that in the cover. I believe UGGA was the opposite of that.
I am switching over to full chrome controls while I am at it, and that is no fun at all. Working inside those switch covers is a drag. I had close to four hours in one side alone before I finally got it right. I sure hope I haven't screwed anything up. Man they are finicky....don't want to open those up ever again.
I did manage to run the throttle cables, but as yet the front end is not ready for them.
What I discovered today is that I WILL have to extend the wiring harnesses (oh joy) including the power to the heated grip on one side from the bike, and the line through the bars from the one grip to the other. The stock harnesses just peek out of the hole in the middle of the bars when pulled through.
Well, I have two days free time left to go. I'll have to solve the thread problem in order to get the clutch issue solved and the exhaust all back on. I still have to tackle swapping the switches into the left side cover, extend all the wiring, and get everything back together, adjusted, and see if the bike will still run after all this.
I am reasonably mechanically inclined, (although I am giving 2nd and 3rd thought to that) and have access to a whole lot of tools.
This job is not for the faint of heart.
If I had to do it all over again I might have someone to do it for me, but I am fussy and don't really want to trust my bike to anyone else. If anybody is gonna screw it up, I want it to be me, (and I'm well on the way to doing just that) but paying someone else to do is looking real good right about now.
CN
Now I'm at the end of Day 2. Things are not going well in my eyes.
Yesterday I was able to tear everything apart and get the forks modified, the RaceTech Gold valves and springs installed, and get the front end back together again. I took my time, but still had 11 hours into it.
Today I put in another 10 hours. In order to access the clutch release cover I had to remove my entire exhaust system. (that was fun...NOT) Turns out I have the same problem as UGGA. The threads on the end of the Barnett clutch cable do not match those in the cover...and I don't know what the thread is. I have gone through all the taps I have, and I have two full sets at hand. The thread on the cable is finer than that in the cover. I believe UGGA was the opposite of that.
I am switching over to full chrome controls while I am at it, and that is no fun at all. Working inside those switch covers is a drag. I had close to four hours in one side alone before I finally got it right. I sure hope I haven't screwed anything up. Man they are finicky....don't want to open those up ever again.
I did manage to run the throttle cables, but as yet the front end is not ready for them.
What I discovered today is that I WILL have to extend the wiring harnesses (oh joy) including the power to the heated grip on one side from the bike, and the line through the bars from the one grip to the other. The stock harnesses just peek out of the hole in the middle of the bars when pulled through.
Well, I have two days free time left to go. I'll have to solve the thread problem in order to get the clutch issue solved and the exhaust all back on. I still have to tackle swapping the switches into the left side cover, extend all the wiring, and get everything back together, adjusted, and see if the bike will still run after all this.
I am reasonably mechanically inclined, (although I am giving 2nd and 3rd thought to that) and have access to a whole lot of tools.
This job is not for the faint of heart.
If I had to do it all over again I might have someone to do it for me, but I am fussy and don't really want to trust my bike to anyone else. If anybody is gonna screw it up, I want it to be me, (and I'm well on the way to doing just that) but paying someone else to do is looking real good right about now.
CN
Road Master
Joined: Sep 2005
Posts: 1,190
Likes: 1
From:
RE: Chubby 513 project
Where did you buy your cables from? I'm looking to do the same on my SG and don't want to run into the mismatch of threaded ends either.
I didn't even think about having to extend my heated grips when I do my bars..that sucks. No slack up under the seat going to the battery?
I didn't even think about having to extend my heated grips when I do my bars..that sucks. No slack up under the seat going to the battery?
Road Master
Joined: Sep 2005
Posts: 1,190
Likes: 1
From:
RE: Chubby 513 project
Just ordered my cables today. Decided to go with the Magnum SS Chromites. A buddy has them and they look great. Didn't want to deal with the issues some people are having with the Barnetts and the threaded fittings not being the right size/thread. +2 on all cable and +4 on the clutch.
Need to order my hand controls now and the bars.
Need to order my hand controls now and the bars.
Outstanding HDF Member
Joined: Nov 2005
Posts: 2,408
Likes: 2
From: Houston (Area)
RE: Chubby 513 project
Turbo,
I'm ordering the same cables. The chromite II. +6 throttle/idle and +8 clutch.
I'm ordering the same cables. The chromite II. +6 throttle/idle and +8 clutch.
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Road Master
Joined: Sep 2005
Posts: 1,190
Likes: 1
From:
RE: Chubby 513 project
I think they are close to the barnett platinum. Since I've seen them first hand on my buddy's bike after several years, I know they will hold up and be looking good years from now.
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Thread Starter
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Outstanding HDF Member
Joined: Mar 2005
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Likes: 4
From: Vancouver, B.C.
RE: Chubby 513 project
I got the bars and cables from Johnny Vaughn. www.hdbikeparts.com
Turns out the threads in the clutch release cover were a bit whacked, not those on the cable end.
I ended up threading in a 5/16" X 24 bolt into the cover to clean up the threads after confirming that a nut that fit the bolt, also fit the threads on the cable end just fine.
Mucho thanks to the suggestion and help from Nick in the Parts Dept. at Trev Deeley HD here in Vancouver.
Today I got all my harnesses extended and run through the bars, completed swapping the controls switches into the 2nd chrome switch housing, got my heated grips wiring hidden away, mounted both left and right switch housings and the clutch mount on the 513s. Now I just have to do is put the harness connectors ends back on, attach the throttle cables to the grip end, and install the brake lines and master cylinder....and put everything else back together.
And, oh yeah, a clutch adjustment issue I've come up against now. (see tech section under driveline/ clutch group)
CN
Turns out the threads in the clutch release cover were a bit whacked, not those on the cable end.
I ended up threading in a 5/16" X 24 bolt into the cover to clean up the threads after confirming that a nut that fit the bolt, also fit the threads on the cable end just fine.
Mucho thanks to the suggestion and help from Nick in the Parts Dept. at Trev Deeley HD here in Vancouver.
Today I got all my harnesses extended and run through the bars, completed swapping the controls switches into the 2nd chrome switch housing, got my heated grips wiring hidden away, mounted both left and right switch housings and the clutch mount on the 513s. Now I just have to do is put the harness connectors ends back on, attach the throttle cables to the grip end, and install the brake lines and master cylinder....and put everything else back together.
And, oh yeah, a clutch adjustment issue I've come up against now. (see tech section under driveline/ clutch group)
CN
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