The main unit.

First job with the injection system was already made when the project went from Sportster to Bigtwin. Buying the EFI system.
I bought the system for the Sportster but when I ordered it I bought another wireharness. Just in case for the Bigtwin and that day came faster that expected.
I went for the DIY open source EFI system, Megasquirt.
This system have a quite large ECU so I went for the already assembled smaller version, Microsquirt.

The eighth winter 14/15

The eighth winter was originally intended for my new project, a custom Sportster build.
But things happens and friends pushed me in other directions.
So this winters lineup are for the old Shovelbagger:
# Completing the seat.
# "Noseart" on the fairing.
# And the main project, EFI.
It was time to take my old comrade in to the twenty first century with some Electronic Fuel Injection.
The EFI job have so many stages so each one makes a project of its own.
The updates will not always be in the right order either.

The Beltdrive saga with 48 tooth

So when the dogcage was done the beltdrive adventures continued.
The good folks at BDL sent me a .020 undersize 48 tooth frontpulley.
Sadly that didn´t solved the problem. The belt was still way to tense.
I even had to do two "clutch hub pushers" to get the rear hub on to the coned shaft, that´s how tense the belt was.

And change from 130 tooth belt to next step, 132 was not possible according to BDL.
Even if the 8mm pich was the same the tooth profile was not.
So if I had used such belt I have destroyed it quickly said BDL.
I took the problem in my own hands and checked the "tooth clearance" between the belt and the stock pulley.
It was some play there so put the stock 48 tooth pully in my lathe and took it down .040.
The .020 that the undersize pulley had plus another .020.

But no still no luck, the belt still was way to tense.

The dogcage

A dogcage?
Yes, life ain´t just motorcycles.
Finally the scratchbuilt cage was done. The frame I made of 20mm square tubing.
I even made the grid out of welding rods and jointed it with silicon bronze.

The little rascal in his new carhome.

Beltdrive issues + dogcage...

The beltdrive circus took of just as the parts landed here in Sweden.
But when I first mounted the new goodies distaster occured.
The belt was to short, or at least that was the outcome.
After talking to my friends who have been wrenchin Harleys since the seventies the common answer was that aftermarket parts are only so you don't had to develop the whole thing but the last bit is all up to you.
Hmmm, was it really this bad? Of Course it was. But thats half the fun.
As the quote goes "If It Was Easy Everyone Would Do It".
*Hehe*
Meassurement begun big style.
The 130 belt was waaaay to short and almost snapped the axels when I mounted it.
Next step in belts was 132 and with this it was waaaay to long.
So after some mails to BDL the nice people sent me a new motor pulley that is .020 undersize.
The project now is to reassemble it all with the new pulley and hope for the best.

But something that halted this project was arriving of a small puppy in our family.
The new little dog had to ride the car with style so the mammoth job of making a dog cage begun.
Have been working with this cage now on and of for two months and now finally I see the end of it.
So soon the belt/pulley problem solving would start again.

Beltdrive/clutch & charging system

Finally I decided for real that the old primary assembly had to go.

This is something I have wanted since day one but now it happend.
The FLT trans had the "clever" lubrication system that should just drip at the chain or whatever the reason was.
Probably this was replaced with the trusty "oil-in-trans" system by the first service interval.
But the FLT trans wasn't made to hold oil in so leaking begun and have continued since then.

A complete BDL kit was ordered and the old stuff was removed and a cleanup begun.
Not only the primary parts was to be replaced but also the charging system.
When I sent for the belt kit I also went for a complete Accel 32A charging system.
It wasn't really something wrong with any of the old chain/clutch/charging but after 33 years it was time for a upgrade.

The tear down begun with full determination so the primary should be empty and ready for the new novelty parts.

The last chain pic

Clean primary waiting for a belt kit

And the novelty parts arrived

The belt kit looked magnificent in it's box

Down to the mancave with all the shiny parts and than the problem started.

To be continued....

The seventh winter (13/14)

This winter there will be both mechanical and cosmetic work done.
# Beltdrive/clutch & charging system
# Ignition
# Seat
# Some paint