Build a Harley

[union]

Yep this is my Harley build thread. It's going to get the same treatment as the rest of the bike I've had.

Day one.

Measurement day and time to make a plan.

[JohnnyV]

Love the colors.... congrats. What's the build plan, or is that being kept a secret?

[union]

Love the colors.... congrats. What's the build plan, or is that being kept a secret?

No secret. Just haven't finalized what we are going to do. It will get the typical mods most bikes get. Exhaust, fuel control some of the other Harley basics. We are going to try to use a set of WP supermoto forks I have on it. I want good forks and brakes. Also going to be doing something on the rear suspension. It will probably be close to a year or so before its 100% complete. The time it takes to make some of the parts and the cost will slow it down at bit. In the end it will be what I think a Harley should be

[SVRACER01]

i can help with some of this.
V&H makes a nice 2 into 1 and use Harleys Super Tuner.
theres some good rear shocks out there. ill check my books when i get to work tomorrow.
HD came out with a LED headlight for that this year too
HD also came out with a hop up kit for that 103

[SVRACER01]

if you decide you want to go really fast, HD came out with a street legal 120 CI motor this year too.

[SVRACER01]

maybe paint the wheels...

[Imbeek]

Cooll looking forward to this...

[bryco13]

Burly makes some decent shocks at good prices. When I went through my sportster, Biltwell and sites like that were a huge help. You keeping the chrome look when you upgrade parts or going black?

[Sheppo]

I can't wait to see where this goes ! *subscribed*

[OreoGaborio]

It's going to get the same treatment as the rest of the bike I've had.

You're gonna let PK race it?

[Chippertheripper]

You're gonna let PK put a hole in it?

Fixt

[union]

The current plan is...

Make my WP forks work
Ohlins shocks
real brakes
typical bolt on shit
detachable sissy bar
good seat

If I can manage to do that without breaking the bank then we will move on from there.

And I did think about taking it to a track day but I doubt that will happen.

[R7]

And I did think about taking it to a track day but I doubt that will happen.

You can do Tony's non sportbike trackdays with that thing.

Don't take this the wrong way, but I'm a lot less excited to read this build thread, than the KTM and R6 builds of the past

[OreoGaborio]

You can do Tony's non sportbike trackdays with that thing.

lol, I was gonna say. Bring it, James! I'll race ya on Jackie's 250

[SVRACER01]

if the WPs dont work, progressive makes a monotube cartridge kit, they also make a nice piggy back in the 970 series for the rear.

also, the calipers are brembo. could probably benefit from a better master though

[union]

Here are the donor forks.



Origanlly I was going to use a set of GSXR forks. They have the same axle size as the Harley. Was hoping to get away with a set of clamps and maybe a different length axle. Unfortunally they are way to short to preserve the look and the handling of the bike.

The forks above will have to be shortened which is a lot easier then extending. The unfortunate side of these forks is the axle is 27 or 28mm and they are only set up for single disc. To achieve what I'm going for I have to get a set of forks lugs made for these and an axle. I'm hoping to finish these 100% complete by next season. The hold up will be time to engineer the parts (fork lugs, axle, triple clamps, and steering stem), time to manufacture the parts, and the money to pay for them plus whatever brake calipers that I'll be running.

Will probably do the first round of bolt on parts ordering this week.

[SVRACER01]

why not just order another lower fork and replace the non brake side?
also, why not just change out the bearings in the wheel to accept the other axle?

[union]

why not just order another lower fork and replace the non brake side?
also, why not just change out the bearings in the wheel to accept the other axle?

As far as I can find is they don't make a right brake mount like that. Magura makes the left side mount for KTM which is what I have. Can't even find that piece for sale by itself. Racetech did make an adjustable axle supermoto fork lug but its left side only and it cost about the same as it will cost me to have a set made.

We did talk about changing the bearings to accept the larger axle. We also talked about sleeving it down and having an axle made which would probably be necessary in any case since there is a slim chance the regular axle is the length we will need. Since we are going to make have to make the lugs anyway we might as well just make them the size we need.

[SVRACER01]

what are the chances that the 990 super moto forks are the same size? that has a pair of brakes on the front.

[union]

what are the chances that the 990 super moto forks are the same size? that has a pair of brakes on the front.

No idea. I could look into them. I already had these other SMR forks in the garage so that is part of the reason we are planning on using those.

[SVRACER01]

i meant if they were the same size forks then maybe you could just order the right side lower from the 990

[SVRACER01]

i just cross referenced. they are different. price new is outrageous too.
if youre gonna put a radial caliper on there, do you think you really need 2?

[union]

i just cross referenced. they are different. price new is outrageous too.
if youre gonna put a radial caliper on there, do you think you really need 2?

No I don't need two. Its something I've been thinking about to reduce the costs. If I ran the same caliper I had on the supermoto I would easily have enough braking power. Would still need an axle and clamps but wouldn't have to make the fork lugs.

[SVRACER01]

i feel like trees and an axle is far easier in both time and money

[tls25rs]

if you decide you want to go really fast,

Give Eric at DAS Performance in Dracut a call. He might know a thing or two about making Harleys go really well.