Build a Harley

[union]

After seeing 340 degrees oil temp in traffic I have made it my next mission to get this thing to run a bit cooler.

I contacted Jagg about adding a second radiator to their system. They assured me that as long as I was using their system it would be ok to add a radiator to the right side.

Yesterday afternoon it arrived.



It was a pretty easy install since I already had the offset filter adapter installed. Just need to attach the radiator and then do a bit of plumbing.

Radiator in place



A bit of hose routing.



Completed.



After I got it completed I went for a bit of a ride today. It was around 80 today and I had a mix of country riding and city riding. It ran about the same temp. 270-290 in country riding depending on what I was doing. It got to about 330 in stop and go traffic. The big difference was how quickly the temp dropped once I got moving again compared to what it did with one radiator. Once I got air moving through it the temps were down about 4 degrees almost instantly and continued to drop as long as I had air moving. When it was just a single radiator it would take longer to cool.

Overall I'm happy with the improvement the second radiator made. I expected better cooling and that's what I got. With that said I do have a set of Wards Fans on order. No idea when they will show since they have been back ordered for most of the summer.

Today I also came up with a new plan for the front end. Originally I was going to use an inverted front end that I had left over from one of my race bikes. Due to costs it would be to make that parts I needed to make it function and look good I've decided to move away from that. Now the plan is to go with the Ktech Tracker cartridges. They are made to go into the Harley forks with just a small modification. They should function the same as the inverted forks I have. They have adjustable preload, compression and rebound. It should also be easier and cheaper to go the dual disc route since I wont have to have complex one off parts made. I should be able to go all Harley. Stay tuned for this. Will probably happen closer to the end of the season or over winter.

[AimlessMoto]

I enjoyed the hell out of this... can't wait for more!

[Imbeek]

Cost/performance of the ktech cartridges vs gold valve emulators for Harley touring forks? I'm looking to upgrade mine

[union]

Ktech retails for about 900 so they cost a bit more. They do give better performance. The emulators are pretty much a band-aide. They are put on top of the damper rod already in your fork to help control the oil flow. They can be somewhat adjusted but you would need to take the forks apart. The ktech stuff is a cartridge system that replaces the stock damper rod setup. They have external adjusters for preload, compression, and rebound. If you have the money I think they are the way to go.

[obsolete]

Ah man, I was excited to see those forks on there. Great job on the build!

[union]

I've stopped updating this as I've done each mod. Since it's a work in progress and will probably never be done 100%. With that said I've done a couple more things to the bike.


First is a set of wards fans.


The install was very easy.





They work great. Riding down the road I will flip them on and the engine temp comes down about 40 degrees in less then 5 minutes. Very pleased.


For those have been on a bike with good brakes know that Harley brakes are horrible at best. Earlier in the build I changed the master cylinder and today I completed the brake job with a new caliper and pads.


Stock brake setup.





Replacement parts.


Speed Merchant radial brake adapters.





Yamaha R6 caliper and Vesrah RJL brake pads.





Checking fit between the caliper and mounting bracket.





Mocked up on the bike get measurements for spacers.








Off to the lathe to make the spacers instead of using the various washes that came with the mounting bracket. New spacers on the caliper.





A quick bleed of the system and its all done and ready to go.








Went for a quick ride after complete. I still need a final bleed of the system to get the lever where I like it but when 100% complete I should have a better feel at the lever and better braking.

[Gecko]

Great job on the brakes, James!

Yamaharley?

[SVRACER01]

First is a set of wards fans.


The install was very easy.





They work great. Riding down the road I will flip them on and the engine temp comes down about 40 degrees in less then 5 minutes. Very pleased.

im sorry, but thats the dumbest thing ive ever seen. i can assure you that it is not dropping the engine temp 40 degrees. if it was that simple (or necessary), HD wouldve installed them in Milwaukee. the engine temp sensor is in that vicinity so its more along the lines of blowing cold air at your thermostat at home to say that its cooler in the house.
besides, with the fans that close, all youre really doing is cooling off one spot. the other side of the engine is still rocket hot so now you have an unevenly heat sunk engine.
you seem to be going through a lot of effort to make your harley a sport bike. maybe you shouldve just bought a sport bike or a vmax.

[OreoGaborio]

Don't be a dink, Oxx. Why would you want an average vmax when you can have an awesome Harley?

[SVRACER01]

a Diavel then? that way you can spend a whole lot of money and still feel entitled and be a whiny bitch.

[Chippertheripper]

Oh snap!

[zombie]

any idea how much the brakes upgrade cost?
thx mick

[union]

you seem to be going through a lot of effort to make your harley a sport bike. maybe you shouldve just bought a sport bike or a vmax.

I'm not sure how putting a good set of brakes and suspension is a lot of effort into turning my Harley into a sport bike. It's mainly a two up bike for me so the added stroke in the shock in nice to have and being able to stop a 700lbs bike is key to me. I'm surprised Harley has made it so far without being taken to court over their shitty brakes for such a heavy bike.

Other then that everything else is pretty much standard mods for most Harleys.

I also don't get why you are so negative over everything I've done. I'm sorry you don't like anything I've done and you think its stupid but oh well. I guess get your own Harley and show me how it's done.

any idea how much the brakes upgrade cost?
thx mick

Well retail costs are

$145 for the mount for the caliper or if you plan on going dual disc its $260 for the pair.

$365 for the master.

Paid $50 for the pair of R6 calipers

Lines and fittings probably around $50. Not sure had them left over from one of my race programs.

$60 for the pads I have.

So $660ish retail. Cheaper then an exhaust pipe and probably better bang for the buck.

Personally I'm into it a bit cheaper then above because of my service time at Computrack Boston. Even at retail I would have still done it.

[Imbeek]

I think it's cool that somebody is putting money into a Harley's suspension and brakes, if they need upgrading for the way you intend to ride it.

On my Road King, the stock brakes (twin calipers in front, one of the big reasons I chose that model) are fine, IMO. Fade isn't an issue and they provide enough stopping power for the tires I run. Suspension upgrades are definitely on my list at some point. I've done other performance and comfort upgrades but I don't think I've bought one piece of decorative or non-functional bling for the bike since new...and don't plan to.

[Garandman]

I'm not sure how putting a good set of brakes and suspension is a lot of effort into turning my Harley into a sport bike. It's mainly a two up bike for me so the added stroke in the shock in nice to have and being able to stop a 700lbs bike is key to me. I'm surprised Harley has made it so far without being taken to court over their shitty brakes for such a heavy bike.

Other then that everything else is pretty much standard mods for most Harleys.

I also don't get why you are so negative over everything I've done. I'm sorry you don't like anything I've done and you think its stupid but oh well. I guess get your own Harley and show me how it's done.

I bought a Roadster, which had a full-height suspension, dual front disks and a tach. Other than an XL1200R it was the most performance-oriented Sportster available. Trying to make it perform was a waste of money and effort, but I learned something.

People who build them do it to have something unique. '32 Ford hot rods do not have impressive road performance, but there is this nostalgic appeal and people don't rank on hot rod owners.

The only reason to spend the time, money and effort on a thing like this is because you want a Harley. Harley is one of the strongest consumer brands in the world, and branding is an emotional process: just look at the money people spend on tshirts and decals.

So arguing facts - that a modified Harley will be heavier, slower, worse handling and less comfortable than almost any alternative - is a complete waste of breath. Rather it is an example of why corporations spend so much money to brand their products.

It's his money and he wants a Harley. The End.

[Imbeek]

So arguing facts - that a modified Harley will be heavier, slower, worse handling and less comfortable than almost any alternative - is a complete waste of breath.

Maybe for Sportsters...

[mikeb]

When you have to spend as much money as you do to buy a Harly you should not have to upgrade basic shit like brakes.

[Garandman]

Maybe for Sportsters...

Go on.....

[Imbeek]

Go on.....

You included comfort in your list of things it's a waste of breath to disagree about. Harley touring models are built for comfort, not speed. They are damn good at what they were intended to do, and that has something to do with why they are so popular.

Put another way: riding a sporty is an insufficient resume to smear all Harleys based on personal knowledge.

Put yet another way: Sportsters suck, and touring model Harleys are pretty cool.

[TheIglu]

Don't worry, he'll post up some Consumer Reports charts next.

[gixxer72]

Don't worry, he'll post up some Consumer Reports charts next.

Or maybe inform us that "the physics are the same" to substantiate total horse shit.

[Garandman]

"Touring model" Harley. Consider me schooled.

[Chippertheripper]

Well, it's not a sporty either, dad.

[Imbeek]

Thanks Garandman, I'm well aware that the OP's bike isn't a touring model. I was referring to both Harleys tested in the racetrack "shootout" you posted a link to (which are touring models). I also own one, like it, and have a good number of miles under the wheels on it, so when someone else says it is slow and doesn't handle, I'm inclined to either laugh and agree, or ride thru some twisties with them and point out that it doesn't handle that poorly, considering its intended role. But when someone says its a waste of breath to argue that (any Harley could be) comfortable, I can only assume they haven't actually ridden the one that is actually designed for that purpose. (LOL)

I've ridden Sportsters too. That's the only reason I feel comfortable saying that IMO, for ME, they suck.

...and I get and agree with your initial post. If he wants to mod a Harley, it's nobody's business but his. Personally, I think it's cool that he chooses to spend money to improve the turning and stopping performance, rather than just the looks. The way I see it, it's the smart place to spend your money on a race bike, and just because the bike you ride on the street isn't designed to be the fastest bike on the planet doesn't change the logic. In fact, it may make it MORE logical than modding a sport bike in areas where it is already pretty good.

[JohnnyV]

Funny, put performance brakes and slicks on a fucking dirt bike and its fine.... Upgrade a few things on a cruiser and you're the butt of a joke. Double standards much?