View Full Version : Keepin busy: 2002 Deuce

Gas Man
10-22-2009, 01:09 AM
I am constantly working on bikes. Generally with the owners, hanging out and sometimes teaching. I don't do it for the money, I do it to help and for the brotherhood.

However...now on the lift, is a 2002 HD Softail Deuce. I have a budget and bardered some home painting for my work. So I guess my first drop off and paid job.

its been rode hard and put away wet several times. Despite its ruff exterior its still a solid running bike. Rides smooth and likes the right grip twisted.

Here's how it came to the garage...
Rusted heat shields from dragging them (bikes from Fort Brag area)

Bald rear tire

Wonder why? See little pieces of burnt rubber

SE tuner

K&N air filter at least

So under close supervision I pulled the rear wheel for tire replacement

Always take a pic of the rear axle and spacers for future reference

Found a broken belt gaurd that I fixed

new rear tire and ready for an oil change

Primary oil was dirty

Adjusted the clutch

New gasket and primary drain plug

Gas Man
10-22-2009, 01:10 AM
Trans oil was in good shape

Engine oil not so much

I also, lubed and adjusted all the cables, lubed up the kickstand which was sticking, washed the bike between rear wheel and oil change, obviously put rear belt deflection to spec when installing rear wheel, checking primary chain, replacing the spark plugs and dielectric both ends of both plug wires... but we continue
As previously shown the exhaust heat shields were BEAT. I removed them

So I sanded them a bit...

Just to realize that was going to cut it and took a sandpaper wheel to them to remove the stuburn rust. Got it all off and used some VHT ceramic on them

About 70% of the tips chrome flaked off so I decided that would go black as well. The bolt on the bottom was ground down so instead of drilling it out and making a larger job of it, simply taped off and used the same ceramic spray

More coats

in the meantime I worked on the shifter assembly of the forward control. it was super sloppy and floppy. Disassembled it

pressed in the new bearings

And you wouldn't believe it... put it back together and its solid and smooth

Gas Man
10-22-2009, 01:11 AM
Finished up the ceramic spray on the heat shields and put it all back together... WOW it turned out great.

I think the black tip looks fantastic on the end

Still to come... I have to pull the dashboard, speedo, gas tank, petcock, and gas gauge. Need to clean the petcock and figure out why the speedo and gas gauge aren't working.

10-22-2009, 01:18 AM
That's great, how long it take you to do all that?

Gas Man
10-22-2009, 01:20 AM
Um... not long. I have done all of it before... I haven't kept track... I have worked allot this week so I haven't had much time to devote to it. Hence why I have left the gas tank stuff for a day off. IDK... maybe 4hrs. I'm just guessing... its been spread over all this week.

10-22-2009, 08:38 AM
Is the guy you're doing the work for the original owner? Is he the one that let it get this way, or did he buy it used?

Gas Man
10-23-2009, 12:29 AM
I think he's the owner. He's a crazy fucker... honestly. He's in army special forces... I just dont think its part of his priorities.

10-23-2009, 09:10 AM
Well, there ain't nothing wrong with a rat bike as long as it's mechanically sound.

Gas Man
10-23-2009, 04:45 PM
True and that is the case here I believe.

Gas Man
10-24-2009, 01:39 AM
Well I'm a bit disappointed in the HD service manual. It gives me next to nothing on trouble shooting these pieces of the speedo/gas problems.

I pulled the dash

Drained and Pulled the tank

Pulled the sending unit from the tank

And this is the only piece that they give any info on for checking the parts

The clip on the back of the swivel of the gauge sending unit was loose. I checked the range operation with ohms and it seems to be in the range specified in the book. The wiring don't look bad at first glance. Need to check for proper voltage on bike and check fuel gauge operation. But with what numbers? The manual gives me nothing.

Same goes for the speedo not working. Nothing for troubleshooting in the manual.

Tells you how to remove it but that's it.

Anybody have any info on testing the gas gauge, speedo, and speedo sensor??? I pulled each unit from the bike and may also see what the dealer says. I'm checking on some hd forums as well. Hopefully somebody has something of numbers so I can troubleshoot the components.

10-24-2009, 10:17 AM
No help here. I do know that Harley sells a service manual and a separate electrical manual for troubleshooting and diagnostics. It sounds like that's what you need.

Do the indicators on the dash work or is the whole thing dead? If the entire dash isn't working you've got a non-specific problem. It sounds like a short in the system. Before you took it apart, did you check the lights? Also, did you check the fuses? Does the bike seem to charge ok?

If it's just those two things, Have you tried: Removing and cleaning the speedo sensor, or even replacing it? From what I've learned that is the number one cause of speedo failure.

The gas gauge, I'm no help at all other than the obvious mundane fuse, broken or rubbed through wire, sensor.

Gas Man
10-24-2009, 02:55 PM
Everything else works fine

Checked fuses...
cleaned speedo sensor...

These things I checked on day one

I'm going to check with dealer later and see what they say. Maybe order other manual.

Somebody told me that the gas gauge will just take 12v. At full 12v it should go full. I'm going to try that in a bit before gg to dealer.

Gas Man
10-25-2009, 01:12 AM
Well I got it figured out. Spoke to the mechanic at the dealer. he gave me a couple a tips. I also found out that if you want electrical help you need to purchase a seperate electrical manual. They are published yearly so I bought one for my set of 2009s. But onward to this project.
First... on the gauge sending unit. He agreed the loose clip I tighted on the pivit pt may be causing some issue. But he said in 2002 or 2003 there was a service bulletin to trim the excess off the float arm. The 1/4" excess hangs up on either full or empty on the inside of the tank.
So I did trim it
Test it by moving the float by hand... Works. Re-installed with a new gasket (old one was dry rotting) and new replaceable sealing screws.
BAM... works with a full tank of 93 octane mixed up with some seafoam.
Second, the mechanic informed me that when cleaning a HD speedo sensor that you must never touch it with your hands, where clean rubber gloves, and clean with brake clean and soft cloth (like microfiber or diaper towel). So if it wasn't screwed up before (proven later it was) then cleaning it with a shop rag would damage it. (I dont get it that but will use caution when handling one in the future. He says its most likely the sensor cause I told him it was covered with shavings when I removed it. So I picked up a new one, which also is a improved (supersuicided version). (pointing at new one)
Got it wired in and yes officer I know how fast I was going.
So I buttoned up the project and calling this one a success. Got everything fixed, tuned, and polished up. All at 50% the budget I was given.

10-25-2009, 08:54 AM
You're right, the speedo thing makes no sense. The dealer told me to pull it out and wipe it off, no special handling intructions. It's just a magnetic sensor completely coverd in plastic.

Seems like someone mentioned the electrical manual in post 11....

Gas Man
10-25-2009, 11:56 AM
Yep, and still stupid IMO

Bagger Dave
12-24-2009, 10:54 AM
Gas....did the owner come and get his scoot? or do you still have it in your garage? forgot to ask ya about that the other night when I talked to ya....

Gas Man
12-25-2009, 02:14 PM
I rode it to his neices house and we stored it there in her garage.

01-30-2010, 02:33 PM
Is that 41 or 47k on the clock? Either way, mine is just a baby compared to this one. I bought mine with just over 16 and stored it with 19...woulda been more, but didn't get her till mid-July. Although...mine does share the same bald tire! LoL I swear the thing eats rubber! No...no burn-outs either. I'm thinking these K591 tires wear a soft compound. Everyone I've talked to that has/had a Deuce or another bike that runs the K591 complains about the lifespan on them.

Gas Man
01-30-2010, 07:21 PM
I honestly don't remember. I can tell you this. The bike's speedo has been non-functioning for years. There is probably well over 60k on the bike.