2004 XL1200R Practical Parts Replacement Interval

[sportster1200]

This will be useful for those who wanna buy the parts off the internet to save cost or minimise downtime before the parts break down.

 

It's actually a record of my bike's maintenance history starting from 2007 when minor problems started appearing and i decided to keep a detail record of what's been done on my bike. I bought my bike brand new in April 2004.

XL1200R Parts Interval Record.pdf

Edited July 10, 2010 by sportster1200

[wolfang]

the page is an error...

[sportster1200]

the page is an error...

 

oops.. the link was ok when i upload it to file factory... anyway reattached in this forum itself

[wolfang]

very detailed record.

 

so minor things coming up only after 50 000 km..?

[bishan]

just curious how much the whole HD engine cost, if the flywheel cost is 2.5k. did you always do maintenance in HD workshop? Sorry, i dont know about HD, hence a bit astonished on the numbers of parts worn out

[sportster1200]

very detailed record.

 

so minor things coming up only after 50 000 km..?

 

on my bike.. ya. actually the first prob to occur was the oil seal on my front fork, but i threw away the invoice so can't rem when it happened. but it was handle by the head mechanic Zul at tat time (before he resign) so i guess it was about 2006, 2 yrs after normal riding (rpm nv gone beyond 4500) on SG road.

[sportster1200]

just curious how much the whole HD engine cost, if the flywheel cost is 2.5k. did you always do maintenance in HD workshop? Sorry, i dont know about HD, hence a bit astonished on the numbers of parts worn out

 

i dunno but according to HD mech n yee from sunburst...its very sturdy n shld last much longer. yup my bike had been service by HD mech since day 1. the list of parts replacement is very long as most of the items can only be access when u open up the engine compartment and since my bike had about 100k km of mileage... the mech choose to change them. some like the gasket had to be change as long as the crankcase is open up.

[wolfang]

thanks man for your valuable info..

[hide]

2.5k for a flywheel change is crazy.

is it normal to change it at 100km?

[sportster1200]

2.5k for a flywheel change is crazy.

is it normal to change it at 100km?

 

maybe not. i had ask the mech to check my bike due to some prob wif the gear changing. then they feedback that they heard a sound coming from the engine area when its turning and when they open it up, found some pieces of worn out spacer/bushing thing lying in the flywheel compartment. They said that the alignment of the flywheel might be affected over time and might damage the chamber (as per factory feedback). so they recommended to change the flywheel as 2004 & up sportster flywheel need to be entirely change (unlike earlier model where the space/bushing thing can be press out and a new one put in. i wouldn't have know the prob exist had the mech not heard the sound and open up the engine. perhaps its a common issue but i rather be safe

[TheYasMan]

Thanks for the helpful data. But i have to say, the list scares the **** out of me.

[sportster1200]

Thanks for the helpful data. But i have to say, the list scares the **** out of me.

 

my bike may had been the extreme case as the mech at the dealer feedback that mine is the first 04 onward sportster that had undergone such extensive maintenance so far. most people with sportster may not have my issue as my bike prob took more beating than the rest cos i rode it to thailand twice, once to phuket and once to chiang mai.

[hide]

wats ur setup? a/c n exhaust changed?

[TheYasMan]

and at what speed did you cruise at?

[Burzum]

looking at the list, the parts are way too expensive. dealer really charges a premium..

 

wow bro from 2007 to present, you've spent a bomb!

[sportster1200]

wats ur setup? a/c n exhaust changed?

 

my bike mostly fitted with stock parts (change rear suspension plus some accessories to improve the comfort level for long dis trip) ..no performance parts at all.

Edited July 16, 2010 by sportster1200

[sportster1200]

and at what speed did you cruise at?

 

on NS highway about 150km/hr ..and on thailand's highway 100~120km/hr

[sportster1200]

looking at the list, the parts are way too expensive. dealer really charges a premium..

 

wow bro from 2007 to present, you've spent a bomb!

 

ya lor... cos i lov my bike for its comfy (customise) on long trip and agility on SG's tight road. intend to keep it so willing to maintain it

[hide]

i guess the stock parts ur having keeps the bike hot.

from wat i read from US forums on sportsters , its alot problem free if u run the bike cool.

hd bikes dont like it hot.

change ur exhaust n air intake. the bike runs alot alot more cooler.

 

http://www.xlforum.net/index.html

 

go check out this forum. lots of super good info to learn.

i just got my hd, i read before i got it n now im stil learnin alot from the forums.

its like the encyclopedia for sportsters, and the guys there are really great at helpin.

unlike sg forums, u get ****ed upside down if u ask common questions.

[TheYasMan]

I'm surprised, 150km/hr is not much. I intend to have trips up north but that list just downright scares me to death. It's very discouraging.

[Burzum]

ya lor... cos i lov my bike for its comfy (customise) on long trip and agility on SG's tight road. intend to keep it so willing to maintain it

 

hmm understand your passion but sometiems you wonder if its worth it.. you spent so much in that few years, sometiems one is better off to get a new bike.. but again its your choice man.