1996 XL1200 1st Time Garage Build (read Bolt-On)

So I figured I would start a build thread to track the progress of my build, although it might be more aptly titled a bolt-on. I have a sweet little garage under my apartment where I do most my work. I can't weld or fabricate but other than that, game on and good times!

Here how it starts:

I recently sold my old bike and with the money from that I bought this 1996 XL1200 with 3,900mi. Bone stock and looks like it literally just came off the showroom floor.









Kill it Slayer!!!

Oh yes, and this is where the magic happens, the ole Trusty Rusty Garage. Tight quarters but cozy.



The Good Times Machine juuuuuuuuust fits in the middle there.

Got my manual



Now it was time to get to work

The first order of business was to remove the stock signals. Those big nasty orange balls hanging off the bike are an eye sore of the maximum. However, I didn't want to just snip wires, I wanted to detach them from the source that way if (and when) I get a fix it ticket (I live in LA) I can just slip them back on and pay the $25 doll hairs. So with a little help from my manual, I went to work:

Here was some of the stuff I used:


Took off the seat and got at that under seat wiring because I was going to detach the rear signal wires from the deutcsh connectors under the seat


Took the bolts out of the rear fender bracket and cover and let the rear signal dangle free


Then opened up the rear signal connector to release the wires


This is what the two wires look like


From there I just routed the wires out from under the rear bracket cover and off come the rear signals



Then I put the new chrome bolts that I got from Home Depot (I made sure they were shorter so they would not hit the rear wheel) and rear signals are off and done.


Now on to the front signals

Look how clean that thing is under the seat! Nice donor material for sure.

Originally Posted by billdozer

Look how clean that thing is under the seat! Nice donor material for sure.

Ya I was shocked!!! The bike still has the factory paint dabs on some of the bolts. I opened up the throttle housing the other day and there were the 2 green factory paint dabs just staring me in the eyes. For a 16 year old bike, I was shocked!

Got some frisco's on the way which I am way stoked about!

The front signals were a wee bit more tricky.

First I unscrewed the lights from the control pods


Then I opened up the head light and got to work on the front Deutcsh connectors which are 12 pin instead of the rear 2 pin but thank you manual, no prob






Pins out


From there it was as simple as pulling out the wires from the back of the headlight and because the wires were external, off they came!


So's not to compromise the integrity of the connector I threw a little electrical tape over the now open holes


Took off the other side


Now no more signals hanging


And there you have it all signals off


I was thinking I have more pics of this and I might write a how-to for removing signals cause it might help some else...

Next will be new bars and grips. I got some stuff coming from Lowbrow. Also am removing the tach. I bought a single speedo housing from a member in the good old classifieds. Have to say, it was pretty awesome. I put up a WTB and in less than a day had a speedo housing on its way from a CC member in MO.

Although I did learn NOT to delete a classified posting. I was pretty bummed cause I lost some miles. I was just trying to be tidy and then BOOM! good bye miles. Won't make that mistake again.

More to come

Originally Posted by KickassSeaBass

Got my manual



Now it was time to get to work

Where did you find your manual? I'm having trouble finding one for my 2000.

Originally Posted by highwayhooligan

Where did you find your manual? I'm having trouble finding one for my 2000.

I found mine on ebay, funny enough from a seller in England. He even had 2 of them, one still in the bag and one a little beat up (thats the one I got, it was cheaper). I would check ebay, amazon, and if all else fails you can get them direct from Harley Davidson. For example if you have a stealership close to you, you can call them and ask for the parts department and they might even have one in stock, if not they can order you a new one.

You can also put up a WTB in the classifieds, I have found some good stuff that way.

Also, in my opinion the factory shop manual is far superior to the Clymer ot Haines manuals. Although any manual is better than no manual. I will keep my eyes out for you and PM you if I come across one.

I didn't find anything on ebay or most other places. I found one on Amazon and after a bit of tossing it around in my head, I went ahead and dropped the $60 on it. Geezus. Pricey for a bunch of paper and ink. But, i hope it'll be worth it. Thanks for the response though. I'm loving your bike so far man. What other plans do you have for it?

Right in seabass...might be riding this Sunday if youre free

Originally Posted by SouthBayBobber

Right in seabass...might be riding this Sunday if youre free

Ya dude, I might be down for sure. I might have to take some photos for a client on Sunday, what time are you thinking? I could maybe do a late afternoon on Sunday or afternoon on Saturday. Might ride down to the Loser Machine sale tomorrow morning. Let me know man.

Mornings are a little better this weekend...Afternoon might be cool though, give me some time to wrench on the new bike a little. Let me know when we get closer to the weekend.

It's been awhile. Any progress SeaBass?

Originally Posted by highwayhooligan

It's been awhile. Any progress SeaBass?

Thanks for asking, sorry I have been out for a while, been looking for work and funds ran a bit dry, put on a different tank, but that's about it. Hoping to get a job soon and then have abit more funds. Ain;t that they way it always goes, you got the time but no money or you got the money and no time.