In the years that I was there, product testing took two forms: component and full-vehicle.

The most well-known component tests were the engine dynamometers. Huge fans blew ducted air across the engines which were connected to dynamometers. Computers controlled the operation which cycled the engine between full load and idle. This allowed multiple engines to be run on off-shifts with only a couple of operators on duty.

The first dyno labs were at the Juneau facility in the basement of the "P&A" (Parts and Accessories) warehouse building across the alley from the main office building. Sometimes when it would rain hard the storm drains would back up into the lab. The buildings were close to 100 years old! Overflow storage from the museum bikes was above the lab. There were two Morgan 3-wheeler cars there from a project to use Harley engines in place of the J. A. Prestwich engines. The project was cancelled because of crankshaft breakage which Harley couldn't afford (this was during the "lean" years) to solve.

In 1997 engineering, styling and most of the test labs moved to the new Product Development Center ("PDC") behind the Capital Drive engine assembly plant. Buildings at Harley are known by the street they are on. Brand new state-of-the-art dyno cells and emissions measuring equipment were installed. The huge acoustics (sound measuring) lab was there as well. Shortly after opening the PDC special leather jackets were commissioned for employees that wanted to buy them. I would guess fewer than 50 were ever made.

Component testing wasn't neglected either ... transmission dynamometers were also created to endurance-test the new transmission, then in development.

Some full-vehicle testing was done in Milwaukee, but largely limited to fuel (carb, then injection) development. Riders, called "calibrators" rode year-round (side cars in the winter) to fine-tune "cold-start ride-away" and general driveability.

Most full-vehicle testing took place at the Talladega test track and surrounding rural roads. There was an in-field road race track where the VR1000 was tested. Also, the "bump course" and braking test areas were there.

High-speed handling was done on the oval. In one test, the rider would take the bike up to 80mph, take his hands off the bars and wiggle his butt to put the bike into a high-speed weave, hoping it didn't turn into a "tank slapper". The number of oscillations before the bike settled down were noted.

In 2001, for the 20th anniversary of TTF special leather jackets were commissioned. I believe fewer than 50 of these were made too, and now that TTF has been closed, no more ever will.

Harley did some testing for a while in Naples, Florida, but this too has been closed. The track was shared with the Ford GT40, then in development.

The PDC is still in operation and full-vehicle testing is now done in Arizona.

I have one each of the special jackets, along with other employee-only shirts which I am selling on ebay (see the ebay section in the forums). Why sell now? I need the funds for carburetors for a rare British car I am restoring. I would like to see them go to Harley rider (we called them "true believers", and it was a compliment) who will appreciate the heritage.

DynoGuy

 

One of my friend's father was involved in full-vehicle testing in the Milwaukee area. They had a roller table set up in the garage at home. He would set it up and lock the throttle, then go out and drink beer. Got one that says "Pabst" on it?

 

I used to work as an engineer for a firm that made the rugged computer data aquisition systems that Harley still uses to do full vehicle testing in Yuma AZ and other places.

Our system is on display at the harley museum in milwaukee.

I have also instrumented race bikes for Keith Code and the California Superbike School.

If you want to know things from my side, I can try to answer questions that aren't blocked by my NDA.