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Discussion Starter #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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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
 

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Good job and all accomplished with a mallet, screwdriver, vice grip and crescent wrench. :)
 

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Discussion Starter #4
Good job and all accomplished with a mallet, screwdriver, vice grip and crescent wrench. :)
Don't forget the WD-40! :D :D
 
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Discussion Starter #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).
 

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Where there's a will there's a fix. Dontcha just love those work-arounds. Sometimes a repair job is 30% thinking, 70% wrenching.
 

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Nice work Brian
 
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Discussion Starter #9
The brushes were fine. Armature/commutator was also cleaned :)
Not sure why I'd want to put in wedge-shaped brushes...
 

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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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Discussion Starter #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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Discussion Starter #12
PCV is installed.
 

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Discussion Starter #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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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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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."
 

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Discussion Starter #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
 

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Good job and all accomplished with a mallet, screwdriver, vice grip and crescent wrench. :)
crescent wrenches are for amateurs. channel-locks are the only way to go.
 

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Discussion Starter #20 (Edited)
crescent wrenches are for amateurs. channel-locks are the only way to go.
I save my channel locks for when I really, really need them.
 
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