Handlebar controls

The old ugly and totally worn out controls was replaced by a used set of Harley V-Rod controls.
Clutch side with hydraulic clutch master cylinder to match the Hurst hydraulic clutch cover.
All of it was repainted in satin black powder coating and new gaskets.
And when it all came together it both looked and worked great.

The totally worn out OEM handlebar controls

The new ones, paired to the ISR 6 pot caliper and Hurst hydraulic clutch cover

Clutch

A need for some serious clutch action was another thing high up on the to do list.
Over the years the cluch wire assenbly hade been worn out.
It was so bad that I had to shut of the engine to get it in neutral when standing still.
I first tried the classic choppertrick to remove one clutch disk and one steel plate.
This did't solve the problem with neutral it just gave a slippery clutch.
So I realized something had to be done so I went hydraulic.
A new sturdy billet trap door for a newer 5 speed gearbox was mounted before a HURST hydraulic clutch cover could go on.

The stock worn out and not so pretty clutch release

The new shiny Hurst hydraulic cluth release

paired with the new billet trapdoor behind

Front wheel

Then it was time for my stock 16" cast front wheel to be replaced by a single disc chrome hub from a newer Harley.
Around this I put shiny chrome spokes and finally a 21" x  3,5" Akront/Morad alu rim.
On the left side I mounted an ISR six pot race caliper and a custom made full floating racing 330mm ISR disc.
The ISR caliper I mounted in the existing left leg bracket with a custom billet aluminum adapter plate i made.
Right leg original caliper bracket was shaved of.
And after that both legs got a bright polish before new seals was mounted.
Finally a new nice black Continental ContiRace Attack Custom 120/70- 21 tire was mounted before it all came together.

First cut is the deepest...

Early mockup to see the difference

(Note the not so rigid cardboard brakedisc)

First I made an adjustable caliper bracket template

Than I made a full scale bracket out of 10mm alu...

...and with that bracket as template I made the final bracket

out of a piece of 10mm alu I got from ISR

The shiny alu Morad 21" x 3,5" rim

The awesome threaded Continental ContiRace Attack Custom

And this is how it's turned out. Not so bad I think

The oilproblem

The summer 2009 after the engine overhaul was a little bit of this and a little bit of that.

But the big problem was a serious oil spill when running.

I layed down under the bike sooooo many times during this summer to locate.

The problem was that the amount of oil pouring out and spreading under the bike.

Because of this it was so hard to locate its origin.

The oilproblem when it still was totally out of control

(this much dripp just standing still at idle)

But I saw it came somewere by the oilpump.

So the first thing to wrench was to remove the oilpump again.

I disassembled the pump and took care of the gasket surfaces.

Very fine wet sandpaper on a sheet of thick glass and slowly start even the surfaces.

And it was some areas that didn't was completly flat but nothing extreme.

The pump went back on the bike again together with new quality gaskets.

And than...? Same result.

Under the completly clean underside again and this time I saw something.

The pour came from behind the pump, between the block and the pump.

Of with the pump again.

It is wery tight between the block and pump so it was hard to see when on the ground looking upp.

But finally with the pump on the bench again I saw a plugged hole with bolt and copper gasket and this was lose.

Sooooo good to have found the problem.

Tight that bolt to specs, and back on the bike....finally dry.

The third winter (09/10)

After a summer of hell with a oil leak on the overhauled motor the autumn ended with a fairly dry driveline.
This winter I wanted to give not only mechanical attention to the racebagger but also cosmetic.

On the agenda this winter was
# Oil problem
# Front wheel
# Clutch
# Handlebar controls
# Seat
# Shocks
# Luggage rack

Side bag brackets

The side bag brackets was in same shabby condition as the lower bag brackets.
I first considered new chrome but I decided it would look better when black.
So they also got black powdercoat and new mounting hardware.

Both the side bag brackets and the small brackets mounted on it got new paint

Lower bag brackets

The lower bag brackets that also doubles as rear exhaust mount had a bad look.
Crome was rusted and was in a general shabby state.
I made small nice nuts that I welded on the backside of the bracket for a cleaner mount.
Than it all got a round of black powdercoat before mounted with new stainless insex buttonhead bolts.

Shiny new black powedercoat instead of the dodgy chrome.

The small nuts I made welded on the backside

Nice stainless buttonhead insex bolts makes a tidy and sturdy connection