Cant wait to see the new ac cover on the Mikuni!!

This thread has became a daily for me.....Now,If only you would do the Race Tech spring install!!

 

After riding a T-Sport for 10 years I just happened upon this site today...

Hogpro...just wanted to let you know I've read every page of this and all I can say is you are quick...!

Bike looks great and can hardly wait to see the radio box mounted...

My T is a 2002 that I bought new after a several month search for a black one. After the T was discontinued I started thinking about the "what ifs"...like theft or crash and started looking for the two most irreplaceable parts...the bags and the cowling..... After a bunch of lost bids I finally scored a set of like new bags with all the mounting hardware for $650.00....this was about 2006. When I checked with the dealership new bags were still available at $750 a BAG.... I also lucked out on a like new black cowling with windshield for about $250.00. They are tucked away safe till they are needed or I sell the bike... The one thing I didn't end up getting because I found out about them too late was the shorty black replacement windshield. It was just tall enough to cover the instruments. But after reading your experience with the short windshield I think I'll leave well enough alone. I also picked up two TALL windshields and will put them on if I ever do another cross-country ride...

Have not done much to the bikes motor other than Vance&Hines ShortShot pipes and a STAGE-1 carb kit and air cleaner. The stock pipes had so much back pressure when I downshifted it felt like I was going over the bars. Generally get in the mid-40s for mileage. With the stock pipe and carb it was 47-53.

One other thing I did... Whoever designed the headlight for HD should be made to ride a stock bike at 100 mph at night on a gravel road...or just hung. That thing is CRIMINAL. I replaced it with a Headwinds reflector and the highest output bulb that I could find and it was passable. Also added a set of MotoLights mounted on a Limby Crashbar and that was about all the light I could get out in front of me...and was still not as bright as the 1976 BMW I sold to get the T. Just before inspection time in May I did a search on LED headlights and found that HD was marketing one...it was expensive...almost $400 but just asked myself what is my life worth.... It was the best investment I ever made to keep myself alive at night. It puts out way more on low than the Headwinds did on high. In addition the High puts a box of light right in your lane over 100 yards out...you can't overdrive the light...

Your bike looks great....I especially like the disc upgrades. With those blackened rotors BLACKED-OUT wheels will look really nice...

Keep it UP!!!

Bob

 

Bob, it is good to hear that someone is reading my thread. I have thought about the LED light too. I think once the time changes and I will be riding to work in the dark daily I will get one of those as well. Thanks for your experience on the issue.

So I started putting the Outlaw a/c on and was close to done, however as i was tightening up the DK breather bolts I snapped the head off one as they are made of aircraft grade aluminum, not steel like most. the worst thing i sI read the directions and it clearly stated to torque them to a specific inch lbs torque, but I was too lazy to go and get my my torque wrench thus the busted bolt. These breather bolts are really cool as they have a pad (sponge) and a screen on top to allow them to breathe. I avhe never seen any suc h thing anywhere and want to thank DK for their creativity with them. I am buying another and will get this on shortly. The good news is that I have decided to use this broken breather bolt which i wil avhe to use an easy out on as an excuse to roder my new heads and 95" kit. I also discovered that with the Mikuni carb the bolts that came with the outlaw a/c are a tad bit too long (the onces that attach the back plate and bracket to the carb) so I will source some that are a tad bit shorter when I get chance. I'm gonna borrow and easy out from the shop and get the broken breather bolt out of the head as soon as the new bolt arrives.

I'll get some pics up in a bit of the kit when I get a chance here.

 

I almost forgot to report a few things. the bike was making a nosie that was really bothering me and it got so bad on the way home Friday I was ready to pull the motor apart.

When I pulled my S/E a/c off here is what I found. Broken on both sides. Did I over torque the back plate to the heads? Dunno. I had already removed this unit numerous times without issue but you see what happened.


Seeing as I broke the aluminum head bolt too I might have been a wee bit agressive. Next time the torque wrench is coming out of it's dusty hiding place.
Here is a pic of the DK Customs outlaw unit. Nice steel fabrication and powder coating. It comes with great instructions that do list the torque specs in big bold letters which I chose to ignore.

So for the install I first removed the Screamin' Eagle air cleaner and such. I avhe never seen a back plate break like this but anything is possible. The gorilla must have put it back on last time. I then used the DK Customs Aluminum Breather bolts to loosely attach the bracket to the heads. The DK back plate then attaches to the carb with bolts that thread through the back plate, bracket and then into the carb. The bolts are a little long for my Mikuni but I'll get some shorter one. The gasket mounts between the bracket and the back plate and is included in the DK kit. They thought this out well and it comes with all that is needed.


I ended up using one shorter bolt to seal it all up and left the other two longer bolts threaded in as far as they would go. On a stock carb this would not be a problem as the bolts can thread right through the holes and comes out the back. Then the air cleaner which is a round K&N filter that sits on a lip on the back plate and get attached via the cover with a threaded stud and a nice polished brass or polished aluminum nut ion the end.

Here are the breather bolts which also come with extra sponges for inside. The screen is held on with a small snap ring.




No pics with the covers yet as I busted the breather bolt prior to getting the cover on. I figure this weekend I'll the rest of it done. I'll just have to ride one of the other bieks this week.

Back to the noise I was having in the motor. I t was sounding like a lifter had collapsed on me. IT was time for an oil change anyway so I drained the tranny and engine oil when I got home Friday. It seems that my bike burns a bit of oil as only 1.5 quarts or so came out of the engine. Could this be related to my noise? I think so. I refilled the motor and started it up and all sounded just fine. I also think the broke a/c was really contributing to the noise on the freeway. Moral of the story...check your oil. I avhe to laugh at myself at this point in time.

Anyway, My new heads and big bore should be here in about a week or so at which time I will do the engine build and show you all how simple it really is to do. I am expecting 95 hp and torque or so. I will be switching to Andrews 37 cams from the 26's I put in originally.

 

I am thinking I am going to start disassembly for my big bore tonight. I'd love to have everything torn down and ready to go for when my cams, heads, cylinders and pistons arrive. The air cleaner is already off so all I avhe to do is drain the tank (my leaset favorite part of the job) remove rocker box covers upper and lower, remove rocker and breathers, remove heads, remove pistons and cylinders. I am thinking if I work on this an hour two a night after work i will be ready for assembly when all gets here not that it really matters as I have two other bikes to ride, but I gotta have something to do after work.

Cams will be pressed out and in here at the shop as we have all that good stuff here. Just gotta source some gaskets for the rocker box covers, some new style breathers, base gaskets and a few sundry gaskets for the cam chest being the screen and brown o ring that can sometimes get smooshed and cause sumping. Now to figure out how to pay for everything. Whoever it was that siad I am fast, I am laughing as this seems like an extremely slow process to me.

 

I almost forgot, I got my mount for the radio box. It is a radio box mount from and FXDP found on ebay for $40. Score. Wrinkle black and all and it will bolt right up. Maybe my bag bushings are in now and I can get this mounted for a mockup pic tonight.

 

This has been great reading and full of useful information and contacts, thanks. I'm not sure about those breathers, I mean if it pukes a bit it would come straight out right? Where's your big bore kit coming from? I've got a set of cylinders and heads in the garage just waiting to be sent out but haven't decided on who just yet, but that will be a winter project for me.

great thread

Jim

 

The breathers are trial and error. If they don't work for my application I will swap them out but I am intrigued by them. They have filters in them to soak up excess oil as well. I'll report back on the big bore once it is installed and I have ridden it as I want to ensure it performs as it should first. It has been my experience that big bore usually causes a little more oil to come out of the breathers as well but I cannot judge until I have used them and according to Kevin 60 W is the proper oil for hit summer temps and if used there will be no blowback. I will have an extra set of heads and cylinders in a few weeks if anyone wants a set to send out as well.

 

glad you got her figured out! i also toss 20oz of lucas oil treatment in my motor on all my changes is a night and day difference to lifter noise!

 

Yeah me too. I'll grab some of that lucas stuff too when I do the rebuild. Kinda funny but I just filled the motor with brand new oil and have to drain it for the rebuild. I didn't really think about that.