Problem: the part is now obsolete. Solution: modify an intake runner servo for a Ford. The Dorman 911-912 servo control is the same part without the correct cable pulley and mount. The mount is easy, a piece of angle cut to size with a couple holes and a slot. The pulley is a little harder. You start by grinding the weld off the existing lever. I then took it o the mill and cut the shaft to size, including the notch to match to the old pulley that I removed from the old servo. We have a laser welder at work and a few pulses of that to hold it all in place. I got it put on the motorcycle and cycled the servo. Crap, the servo was shipped in the open position, not the closed (home) position. I attached the pulley in the wrong place.
The shaft is a pain to machine. You have to hold the unit in the mill by the plastic housing. The shaft has some free play. I ground away the laser welds and re-cut the notch. Not there wasn't a good enough fit for the laser (it really likes a nice tight fit). So I TIG tacked it back on. This is also a pain since the shaft gets hot and goes through a plastic housing. I finished it off with some epoxy to fill in the gaps.
All this too say that it sucks that HD closed Buell. It is a pain that parts are obsolete. However, with some elbow grease and patience, we can keep these things on the road for a long time.
|For reference, in the closed position the pulley flat nearest the cable hole will be parallel to the housing nearest the wire connector.|
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