Hilly's 1999 XL1200S

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Hilly's 1999 XL1200S

2/3

speedzter
21 days ago

That's excellent 👍
Good breeding stock 😁
You have definitely earned the title .

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Hilly
17 days ago

Got the new bars today, did a test fit to make sure the brake line will work, a 1/4" longer P clamp at the tree's will give it slack, needs new lines, bit ugly up close but it will pass rego with a bit of spit and polish, the bar bend is good, I'll ride it for a bit to see if I need longer risers or leave as is.

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Hilly
15 days ago

I think I mentioned earlier that the choke (enrichener) cable is broken, held together and in place with cable ties and didn't do squat unless you held it by hand or put a peg in the gap.
As it needed to be changed to pass rego, today I pulled the black oily thing (carburetor) off to change the cable.
In the process I could see that every vacuum line was badly split, the petcock needs vacuum to keep the fuel flowing so it must of had some as the bike runs.
The MAF sensor needs system vacuum to send the correct signal to the ignition module so it does its job properly plus there would be a bit of unfiltered air is getting sucked in.....
I believe the split hoses to be the main contributor to the oily state of the carburettor!
I previously mentioned that I could see the intake mixture screw(henceforth called the IMS) aluminium bung had been drilled out.
I suspected someone would of tried to tune any lean farts out caused by the first split I initially discovered at the carby nipple.
I gave the carby a good bath and a scrub to get the gunk off it before I started fiddling around too much.
Then I carefully turned the IMS in counting the number of turns as I went, after 4.5 turns without bottoming it out I gave up and removed it.
I've read the max you should ever go is 3.5 turns out from lightly seated, after that it isn't doing any real metering and is in danger of vibrating out in operation.
I decided at this point to strip the whole thing to check the internals for any other problems and to see what the jets and needles were and what condition they were in.
There was tiny amount of sediment in the bowl, bugga all, no evidence of any jets being blocked, on the whole I was quite pleased with it, I completely disassembled it for cleaning, I haven't done that yet, tomorrow job.
Both diaphragms are in good nick, soft and pliable, no holes etc, the slide does have a few rough edges that I will smooth off before it goes back in and happily the slide vacuum port has not been drilled out.
Just for the record the main jet is a 200, the pilot is a 45 and the needle is a N86K, to the best of my knowledge they are the stock components for a 1999 XL1200S international model, bonus.

There are about 12 inches of these lines.

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Hilly
14 days ago

With a few bits and bobs I can reduce the vacuum lines to zilch, a little doctoring to the fuel tap to make it work like a non vacuum one, easy job, I'll be changing the tap out eventually anyway.
Found a map sensor extension harness that will enable me to move the sensor onto a 2004 manifold which I got off eBay, a couple of 1/4" rubber blanks and all that hose is gone, well that's the plan.

New hose......

Harness

Second hand discontinued 04 manifold

obisteve likes this post

speedzter
14 days ago

The tinkering has well and truly began !

I was thinking, probably not many RWC shops on the island !
How do you go if you need to present a vehicle to the TAS transport services ?

Hilly
14 days ago

They generally cut us a bit of slack because of location, if Tas transport got real pushy the local coppers would have to get involved, they are not mechanics so I guess they would just look over Geoffs shoulder while he does his thing.

obisteve
14 days ago

If you're gonna change the tap Hilly, I'd thoroughly recommend a Golan. Mine has been trouble free since 2010, except one episode of freezing solid. Gotta love a lifetime warranty, Rollies posted me a free replacement no questions.

Hilly likes this post

Hilly
14 days ago

Quoting obisteve on 07 Nov 2025 10:39 AM
If you're gonna change the tap Hilly, I'd thoroughly recommend a Golan. Mine has been trouble free since 2010, except one episode of freezing solid. Gotta love a lifetime warranty, Rollies posted me a free replacement no questions.

Great minds an all that :), they have a good rep and the positive click positions put me over the line on them, will do 5/16 from tank into carb mod soon, CV Performance have a 5/16 brass inlet for the carby, the plastic one on my carby has surface cracks where it meets the brass so it's days are numbered.

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speedzter
13 days ago

I use a Golan to feed a 48mm Mikuni.
Rated around 3 litres per minute.
Big increase over the stock vacuum tap.

Golan do a nice inline filter too.

Hilly
9 days ago

Quoting speedzter on 07 Nov 2025 10:08 PM
I use a Golan to feed a 48mm Mikuni.
Rated around 3 litres per minute.
Big increase over the stock vacuum tap.

Golan do a nice inline filter too.

What sort of an animal needs a 48 Mik and 3 litres a minute!
I think Mikuni should pay Aaron a permanent commission, I just read something he wrote about HSR's and it made me want to run out and buy one lol, will see how the little 1200 feels with the CV dialled in, if I want a faster throttle response I may get one but not just now, the Golan tap however is on the short list.

obisteve likes this post

Stuart
9 days ago

Quoting speedzter on 07 Nov 2025 10:08 PM
I use a Golan to feed a 48mm Mikuni.
Rated around 3 litres per minute.
Big increase over the stock vacuum tap.

Golan do a nice inline filter too.

Quoting Hilly on 12 Nov 2025 07:43 AM
What sort of an animal needs a 48 Mik and 3 litres a minute!
I think Mikuni should pay Aaron a permanent commission, I just read something he wrote about HSR's and it made me want to run out and buy one lol, will see how the little 1200 feels with the CV dialled in, if I want a faster throttle response I may get one but not just now, the Golan tap however is on the short list.

I wondered the same thing. I'm guessing they don't call him Speedzter for nothing :-)

speedzter
8 days ago

Haha, more slow than speed lately !!
The 48mm Mikuni is feeding my long term project 120" twin cam in an FXDX .
I had more plans for it to bump it up to ~150 hp/TQ, maybe a retirement project now.
I know the WFO Larry's heads and S&S crank I'm using will support it😁😁

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Hilly
6 days ago

Gave the carby a bath in the ultrasonic cleaner, bits came out pretty clean and smelling nice.....really need something a bit stronger.
Ran carby cleaner through the plumbing, two of the transfer ports were a bit blocked, bent up an oxy tip to poke in there to help free up the varnish or whatever it was.
Holding the butterfly open got tedious so carved up a bit of wood to prop it open, holding fingers over ports while trying to spray cleaner where I wanted it had my brain doing contortions so I made little temporary bungs, that made things much easier.
I couldn't get a pic of all five transfer ports doing their best Old Faithful impersonations because I run out of hands.
I ran cleaner through from all three directions that connect to the transfer ports by blocking the the other two off with bungs or the idle mixture screw depending on which direction I wanted it to go, switched around a few times untill I was convinced they were all clear as they can be.
Hopefully put it back together this arvo.

408
6 days ago

What did you use in the ultrasonic cleaner ?

Hilly
6 days ago

Quoting 408 on 15 Nov 2025 12:46 AM
What did you use in the ultrasonic cleaner ?

Look to the top right of the cleaner and you can see 🙈

408
6 days ago

Quoting 408 on 15 Nov 2025 12:46 AM
What did you use in the ultrasonic cleaner ?

Quoting Hilly on 15 Nov 2025 01:02 AM
Look to the top right of the cleaner and you can see 🙈

OK
And if you go to something a bit stronger, what would you use ?
And does the missus have that too, or you would have to buy your own ?

Hilly
6 days ago

Quoting 408 on 15 Nov 2025 12:46 AM
What did you use in the ultrasonic cleaner ?

Quoting Hilly on 15 Nov 2025 01:02 AM
Look to the top right of the cleaner and you can see 🙈

Quoting 408 on 15 Nov 2025 01:27 AM
OK
And if you go to something a bit stronger, what would you use ?
And does the missus have that too, or you would have to buy your own ?

Lmao, I have read that Simple Green is ok, I would double check before using it though, I'd have to buy that myself 😁 you can get fancy chemicals specific for the task but I dunno what's what or where to get it, detergent gets most of it, all of it would be better.

408
6 days ago

Quoting Hilly on 15 Nov 2025 01:02 AM
Look to the top right of the cleaner and you can see 🙈

Quoting 408 on 15 Nov 2025 01:27 AM
OK
And if you go to something a bit stronger, what would you use ?
And does the missus have that too, or you would have to buy your own ?

Quoting Hilly on 15 Nov 2025 01:57 AM
Lmao, I have read that Simple Green is ok, I would double check before using it though, I'd have to buy that myself 😁 you can get fancy chemicals specific for the task but I dunno what's what or where to get it, detergent gets most of it, all of it would be better.

The yanks like Dawn but we don't have it here. I looked for equivalent but got some Dawn Platinum off ebay about 12 months ago. Haven't used it yet. Amazon also have it I think.

B0nes
6 days ago

Quoting 408 on 15 Nov 2025 01:27 AM
OK
And if you go to something a bit stronger, what would you use ?
And does the missus have that too, or you would have to buy your own ?

Quoting Hilly on 15 Nov 2025 01:57 AM
Lmao, I have read that Simple Green is ok, I would double check before using it though, I'd have to buy that myself 😁 you can get fancy chemicals specific for the task but I dunno what's what or where to get it, detergent gets most of it, all of it would be better.

Quoting 408 on 15 Nov 2025 02:57 AM

The yanks like Dawn but we don't have it here. I looked for equivalent but got some Dawn Platinum off ebay about 12 months ago. Haven't used it yet. Amazon also have it I think.

I did some research a while back as I wanted to use Dawn for cleaning watch parts in the ultrasonic cleaner. Was told that it worked really well. My research showed that this was basically the same. And easy to get

Fairy Dish soap

Hilly
6 days ago

Quoting Hilly on 15 Nov 2025 01:57 AM
Lmao, I have read that Simple Green is ok, I would double check before using it though, I'd have to buy that myself 😁 you can get fancy chemicals specific for the task but I dunno what's what or where to get it, detergent gets most of it, all of it would be better.

Quoting 408 on 15 Nov 2025 02:57 AM

The yanks like Dawn but we don't have it here. I looked for equivalent but got some Dawn Platinum off ebay about 12 months ago. Haven't used it yet. Amazon also have it I think.

Quoting B0nes on 15 Nov 2025 07:24 AMedited: 15 Nov 2025 07:25 AM
I did some research a while back as I wanted to use Dawn for cleaning watch parts in the ultrasonic cleaner. Was told that it worked really well. My research showed that this was basically the same. And easy to get

Fairy Dish soap

I thought it was bad enough using morning fresh haha, I'll see if they have it in town BOnes, failing that I'll give 408's stuff a look as well.
Cheers 👍

B0nes likes this post

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2/3

Hilly's 1999 XL1200S

Hilly's 1999 XL1200S

speedzter

Hilly

Hilly

Hilly

speedzter

Hilly

obisteve

Hilly

speedzter

Hilly

Stuart

speedzter

Hilly

408

Hilly

408

Hilly

408

B0nes

Hilly