{"id":31935,"date":"2026-01-21T00:01:39","date_gmt":"2026-01-21T08:01:39","guid":{"rendered":"https:\/\/exhaustnotes.us\/blog\/?p=31935"},"modified":"2026-01-26T07:57:36","modified_gmt":"2026-01-26T15:57:36","slug":"buell-fever-part-3-an-own-goal","status":"publish","type":"post","link":"https:\/\/exhaustnotes.us\/blog\/index.php\/2026\/01\/21\/buell-fever-part-3-an-own-goal\/","title":{"rendered":"Buell Fever Part 3: An Own Goal"},"content":{"rendered":"
By Joe Gresh<\/h6>\n

I’ve been ordering parts for the Buell as I dismantle the beast for service. I really like the way Erik Buell wrapped his tube frame around the 1200cc V-twin Harley lump. The bike is all engine and actually looks even better with the bodywork removed.<\/p>\n

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A new carb for $44! Tariffs? Never heard of her.<\/figcaption><\/figure>\n

I’ve got the carb off and apart.\u00a0 It looks pretty clean inside, and the bike probably would have run fine, except for the rubber tip on the float needle. It has a pronounced ridge that may or may not have caused a flooding issue.<\/p>\n

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The kickstand culprit. This worn area was the locking boss. It’s wiped out so no locking. I may weld it up and relocate the pivot to allow for over-centering (eliminating the lock system).<\/figcaption><\/figure>\n

The Buell has a strange kickstand (another bike with a goofy kick stand; see the Husqvarna kickstand story<\/a> here on ExhaustNotes). The stand has an elongated mounting hole that allows the stand arm to pivot up and down in addition to the normal fore-aft motion.\u00a0\u00a0This extra motion was designed to allow the square pivot end of the stand to drop into a notch cast in the frame mounted, aluminum foot peg\/kickstand boss. That’s a mouthful but when you see it it’s easy to grasp the concept. When new this setup made for a locking stand when deployed with the bike’s weight bearing on the stand.<\/p>\n

The operative words here are “when new.” On my Buell the notch area inside the kickstand boss is worn out and the stand no longer locks. As built the stand doesn’t over-center and naturally stay in place like normal kickstands. You know where this is going. Fixing the kickstand was on my Buell to-do list. I should have made it job one.<\/p>\n

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Kickstands break levers. Ask me how I know.<\/figcaption><\/figure>\n

As I was removing the carb (standing on the right side of the bike) the Buell started rolling forward. As it fell left I held onto the frame as best I could but the bike hit the ground hard breaking the clutch lever. The right mirror, which is also a faring mount, took a hard hit and things look a bit off from the cockpit. I have the bike on jackstands now and it’s stabilized.<\/p>\n

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Jack stands after the horse has left the barn. At least I stopped dropping the bike.<\/figcaption><\/figure>\n

Luckily, I had most of the bodywork removed and the only bits left, the front fender and fairing, are unscathed. $20 will get me two new levers (Harley parts are cheap!) but I think I’ll just weld the broken tip back on. You know, to keep it original.<\/p>\n

Back to the carb. The Buell motor is a stock 1995 Sportster mill and there is a huge parts aftermarket serving the Sportster. The carb kit was $13! I can get a complete, clone carburetor with new spark plugs, fuel filter and jet cleaning tool for $44! I know, I know, it’s Chinese but who’s to say the original isn’t Chinese? The Amazon clone carb reviews are positive: just bolt it up and the bike runs great. I bought the kit but that new carb was tempting.<\/p>\n

This 1995 Sportster is quite a bit different than my old 1968 Sportster. The bottom end looks similar but everything else is different. What I thought was a pressure feed for oiling the top end seems to be a vent as the hose ends under the battery with the hose end left open to the breeze.<\/p>\n

There’s also a rubber grommet with an open hole in the filtered side of the air cleaner. I suspect a crankcase vent hose went there but I’m not sure. As is, the hole allows unfiltered air into the carburetor so that’s not good. I’ll plug the hole or figure out what goes in it.<\/p>\n

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Plugs look a little sooty. I’ll clean them up and flog the bike to blow out the soot.<\/figcaption><\/figure>\n

I don’t know how long the Buell sat so I pulled the iridium spark plugs (sooty) and squirted some motor oil in the cylinders so the rings don’t have to scrape on dry bores. When I get a battery, I’ll give the motor a spin with the plugs removed to blow out any excess lube.<\/p>\n

Apparently, the White Power front forks on the 1995 S2 are different from the following years. I’m having trouble finding fork seals and have emailed White Power directly. No response yet. If I had a 1996 S3 fork seals are everywhere for the damn things.<\/p>\n

For me, the rear tire was a little too close to the Buell’s underslung muffler. Like a 1\/8″ gap. It looks like the muffler slid back a bit from the header pipe. I loosened the pipe clamp and mounting bolts then beat the muffler forward with a rubber mallet.<\/p>\n

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Does this tire gap make me look crashed? Not much clearance, Clarence.<\/figcaption><\/figure>\n
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Hammers and jacks gained quite a bit of clearance. I have no faith in this fix.<\/figcaption><\/figure>\n
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Buell tools. Anvil and forge not shown.<\/figcaption><\/figure>\n
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I think the permanent fix is to make these brackets a bit longer so the muffler fits the header better. Then weld the brackets on the muffler side to prevent the parallelogram effect when the bolt clamping inevitably loosens.<\/figcaption><\/figure>\n

A jack under the header pipes pushed the header into a more agreeable position and I tightened the bolts. This beating gained about 3\/4″ but I’m sure it won’t hold. The muffler looks like a new one or freshly painted. The angle of the header pipe isn’t quite right.\u00a0 The tail of the muffler needs to drop about 1\/4″ which means slightly longer muffler brackets. Once the bike is operational, I may do some exhaust re-engineering.<\/p>\n

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$30 seems cheap but then I’m approaching the end so I’m risking less.<\/figcaption><\/figure>\n

The rear brake Brembo master cylinder is stuck and will need to come apart along with the rear caliper. Seals for the rear brake components are another hard to find item. I did find a Brembo clone master cylinder\/caliper\/brake line set up that may fit for $30 so I bought that. Watch for the ExNotes Brembo-clone brake system review.<\/p>\n

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Wiring straight out of 1960. I love it.<\/figcaption><\/figure>\n

Except for the damage I’m causing by dropping the Buell, it looks to be in good shape. I probably could have poured gas in the thing, popped a battery in and gone for a ride. Who needs a rear brake anyway? I’ll be dismantling the front end soon to measure the fork seals and to give the steering head bearings a shot of grease.<\/p>\n

That 6-mile Cyclone (the one I didn’t win) is looking more and more like a steal!<\/p>\n

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Buell Part 2:\u00a0 The Reckoning<\/a>
\nBuell Part 1:\u00a0 More Cowbell<\/a><\/p>\n

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Join our\u00a0Facebook ExNotes page<\/a>!<\/p>\n

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More Joe Gresh?\u00a0 \u00a0It\u2019s right here:<\/p>\n

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Help us keep the lights on:<\/h3>\n
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By Joe Gresh I’ve been ordering parts for the Buell as I dismantle the beast for service. I really like the way Erik Buell wrapped his tube frame around the 1200cc V-twin Harley lump. The bike is all engine and actually looks even better with the bodywork removed. I’ve got the carb off and apart.\u00a0 … Continue reading “Buell Fever Part 3: An Own Goal”<\/span><\/a><\/p>\n","protected":false},"author":2,"featured_media":31942,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":true,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[654,235,392,96,452,103,66],"tags":[4827,4828,4829],"class_list":["post-31935","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-adventure-motorcycle-books","category-amazon","category-back-in-the-day","category-feel-good-stuff","category-harley","category-harley-davidson","category-joe-gresh","tag-1995-buell-cyclone","tag-buell-maintenance","tag-buell-repairs"],"jetpack_featured_media_url":"https:\/\/exhaustnotes.us\/blog\/wp-content\/uploads\/2026\/01\/IMG_2634-900.jpg","jetpack_sharing_enabled":true,"post_mailing_queue_ids":[],"_links":{"self":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/31935","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/comments?post=31935"}],"version-history":[{"count":10,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/31935\/revisions"}],"predecessor-version":[{"id":32101,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/31935\/revisions\/32101"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/media\/31942"}],"wp:attachment":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/media?parent=31935"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/categories?post=31935"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/tags?post=31935"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}