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Broggy's Winter Work 2016-2017

49K views 414 replies 35 participants last post by  Motorbikerx 
#1 · (Edited)
Instead of clogging up the "What did you do today" thread, I figured I'd make my own. Easier to find and update.

Anyway, today I tore the bike apart. I need to pull out the starter because it squeals like a whiny bitch when its cold. Also, I have a brand-new PCV to be installed, and I want to (re)install my iPod cord (from when I removed my lowers).

It was 17 degrees when I woke up; good thing I didn't have to work today. First thing I did: fired up the kerosene heater!

Removed the exhaust and pulled the starter. No rust in there (whew!), but lots of iron filings. Cleaned everything out, cleaned and regreased the bearings, and reassembled the motor. So far, no more squeals!

Next up:
Removal of the VFC III and installation of the PCV... (stay tuned)
 

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#2 ·
Instead of clogging up the "What did you do today" thread, I figured I'd make my own. Easier to find and update.

Anyway, today I tore the bike apart. I need to pull out the starter because it squeals like a whiny bitch when its cold. Also, I have a brand-new PCV to be installed, and I want to (re)install my iPod cord (from when I removed my lowers).

It was 17 degrees when I woke up; good thing I didn't have to work today. First thing I did; fired up the kerosene heater!

Removed the exhaust and pulled the starter. No rust in there (whew!), but lots of iron filings. Cleaned everything out, cleaned and regreased the bearings, and reassembled the motor. So far, no more squeals!

Next up:
Removal of the VFC III and installation of the PCV... (stay tuned)
That looks like some great progress Broggy! Kudos!

Side note, I'm oddly elated to see that my bike is not the only one with a dirty engine.:grin
 
#3 · (Edited)
Good job and all accomplished with a mallet, screwdriver, vice grip and crescent wrench. :)
 
#4 ·
Don't forget the WD-40! :D :D
 
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#5 · (Edited)
So, the biggest question in my mind regarding this starter rebuild was "How am I going to hold back all of those brushes at the same time?" when it came time to reinstall the armature. I watched many videos. Every single video I saw all had the brush plate separate from the end cap. Did you know the Vic starter brush plate is bolted into the end cap? I didn't have anything springy or clampy enough to hold these back. I was in a bit of a pickle. In the back of my mind, I figured I'd probably have to buy a new starter.

One of the videos I was watching was for a Briggs-and-Stratton starter. The guy said you could buy a new brush plate and end cap as an assembly, the brushes were held back by baling wire. This got me thinking. So I took a look at the brush plate in the Vic starter and sure enough, there are small recesses that would be perfect to stick in a paperclip.

So, I took 2 paperclips, straightened them out, then cut them in half so I had 4 equal-sized pieces about 2 inches long each. I was able to push a brush back into its holder, slide it all the way back, and hold it into place with the paperclip piece. I was able to do all 4 brushes, slid in the armature, then pulled the pins out.

Worked like a CHARM.

Then, I realized I forgot to replace a couple of the bushings; I had to do it all over again. The sweet thing was, it was just as easy to do it all over again.

I only wish I had thought to stop and take photos; I was so excited that it was actually working...

Now, I just hope that what I did fixes that god-awful noise when it's cold out. It's certainly better than buying a new one for $75-100 (aftermarket).
 
#6 ·
Where there's a will there's a fix. Dontcha just love those work-arounds. Sometimes a repair job is 30% thinking, 70% wrenching.
 
#7 ·
Nice work Brian
 
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#9 ·
The brushes were fine. Armature/commutator was also cleaned :)
Not sure why I'd want to put in wedge-shaped brushes...
 
#10 ·
Those "aftermarket" starters aren't aftermarket they are the exact same ones Victory uses right down to the numbers stamped on them. I bought one for my Vegas the same one Vic wants $100's for and it was an exact match.
 
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#11 ·
Interesting. Maybe buy one and keep for a spare? Next time this starter acts up, just swap them, then rebuild?
 
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#12 ·
PCV is installed.
 

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#13 ·
This is on my spring mod list before dyno tuning trip to Lloydz the end of April!
 
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#14 · (Edited)
Can't wait to get this thing back on the road for a test ride!
Next on the list:
- Reinstall exhaust (waiting on gaskets and O2 plugs)
- iPod cable reinstall (waiting on extension cable)
- Magnum speaker install
- Have to rewire the Sabertooth lights (the wire is almost chafed straight through from the saddlebag lid)
- Dyno tune (in the springtime)

I will probably be selling my VFC III...
 
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#15 ·
Impressive broggyr! Finally got my XR out, it had been blocked in by 1000 square feet of carpet and other crap from putting down hardwood in my house. 44 degrees in TN today so I took the day off and going out for a ride after lunch. I think I too am finally going to do the PCV-timing wheel-dyno thing this year but I noticed Lloydz doesn't have a link to upcoming dyno tuning events like he had in the past on his website.
 
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#21 ·
From East TN, I'd go to see Southern Motorworx in High Springs, FL. The trip back after letting KevinX do what he does so well would be awesome. I met Kevin recently and he's an awesome guy. Kevin also does a lot of traveling with his dyno in a trailer set-up so you may want to check his schedule. His phone number is: 352-216-3253.
 
#16 ·
Broggy, O2 sensor hole plugs can be had FREE at any muffler shop. Pipes and cats come in with 'em and are removed and thrown away. The carts the techs use usually have 'em strewn about in 'em. There are two styles - I got the ones with an allen recess, so its flush and "invisible."
 
#17 ·
From what I understand, Lloydz only does tuning now at his Pinebush, NY location. Any mobile dyno events for Lloydz are now handled by KMC Powersports from Rhode Island.

KMC Powersports
 
#24 ·
Thanks @RICZ for the info about the O2 plugs. Unfortunately, I don't have a muffler shop, etc. near me to make it worth my while. I spent $11 on a pair and tracking says I'll get them tomorrow :)
 
#25 · (Edited)
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#26 ·
Tore the inner fairing apart tonight...

Removed the inner fairing so I could get at my speakers. Also an excellent opportunity to get in there and clean things up. I'll also be replacing the cigarette lighter with a USB port, since all I use it for is charging my cellphone or GPS anyway...

Question for everyone: I am toying with the idea of painting my chrome dial bezels blue to match my bike. The rest of the inner fairing would remain black. Heck, I might even paint my speaker grilles to match. What do you think? Opinions?
 

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#28 · (Edited)
Removed the inner fairing so I could get at my speakers. Also an excellent opportunity to get in there and clean things up. I'll also be replacing the cigarette lighter with a USB port, since all I use it for is charging my cellphone or GPS anyway...

Question for everyone: I am toying with the idea of painting my chrome dial bezels blue to match my bike. The rest of the inner fairing would remain black. Heck, I might even paint my speaker grilles to match. What do you think? Opinions?
Brogster, a couple of comments:

Having ODed on chrome with my Valkyrie Interstate for seven years, I'm all for turning the bezels blue. But that's a personal thing.

More importantly, you might want to exercise some caution with the cigarette-lighter-to-USB swap. I certainly agree with you on the concept: I never use the lighter socket except for plugging in USB stuff (e.g., a phone charger), and I have two added Powerlet sockets, and corresponding male plugs on heated gear, smart-charger, and air pump. And I also have an added USB outlet on the dash.

The caution involves parasitic draw. Unless you change the wiring setup, that outlet -- and hence its replacement -- will be always hot. That's no big deal, and often convenient (e.g., smart-charging), in stock setup. However, USB outlets always draw some current, even when not in use, because there are tiny transformers inside them.

So you might want to have a USB outlet hot only when the bike's running. That's how I have mine wired (a 3BR Panel TAPP -- see https://www.3brpowersports.com/products.php -- and a corresponding trick cord for my GoPro and 3BR's case).

I started a thread on this a couple years ago, and the results were decidedly mixed. Some folks -- and there are a lot of them -- with always-on USB outlets in the saddlebags, for instance, said no problem-o. Others said, yeah, it was a problem.

3BR itself, in the instructions for the Panel TAPP -- see https://www.3brpowersports.com/PDF/PanelTAPP_2_1.pdf -- says, "It is recommended that TAPP be connected to a switched power source to prevent battery drain when the vehicle is not running."

So, do what you like, of course, but consider yourself warned.
 
#30 ·
First off write Kevinx and Kycle and see what rallies there going to attend and when. You might get lucky


broggyr
As close as you are paint the hole inner faring. You have the time winter is coming your way big time. So paint it

by the way 6 above today with windchill -27 with 14 mph winds, and towarow will be worse. Sorry guys its headed east
 
#31 ·
Just got in from snowblowing (not too bad), here in eastern NY:
 

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#32 ·
Keep your blowers and shovels handy - the storm that was here in Portland is working its way eastbound to a driveway near you. Hopefully, your drivers can handle it better than Portland's car movers (I can't lower myself to call them drivers).
 
#33 ·
Thanks for the heads up @wspollack about the always-hot lead. I intend to do that very thing.
@visionjohnny I thought about painting the whole thing, but I'm worried about scratching it up when I replace it. I do have a can of 'official' boardwalk blue on the way however, so it won't be totally out of my mind... :)
 
#35 ·
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@visionjohnny I thought about painting the whole thing, but I'm worried about scratching it up when I replace it. I do have a can of 'official' boardwalk blue on the way however, so it won't be totally out of my mind... :)
Do it , I did mine and no scratches upon installation . It looks great when it matches the ride too .
 
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#34 ·
I also just got done blowing my driveway; it said "Thanks!" :D :D
It was about 4" of that heavy wet stuff...
 
#36 ·
Do it Broggy!

You guys are killing me with the snow. I love it. Instead of tubing on the hills with my friends, I am out riding. I paid for a nice cabin in the mountains so I can have a white Christmas! Instead, just like last year, they are predicting cool and rainy!

Sent from my SAMSUNG-SM-G870A using Tapatalk
 
#44 ·
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#37 ·
Paint it. Go slow on install. Put tape on cables and what ever to prevent scratching. Do not put tape on painted parts.


-2 now 10 inches of snow is plowed. Going down to -40 below windchill.
Hwy patrol reports 700 accidents one death.
wish I could move
 
#38 ·
-2 now 10 inches of snow is plowed. Going down to -40 below windchill.
Hwy patrol reports 700 accidents one death.
wish I could move
Come on out to Portland where we do it better--1" of snow, 100s more wrecks and 5+ deaths and still counting. Our amateur drivers are experts at being amateurs.
 
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