K9 Rebuild/Upgrade

82ndAirborne

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So...my lucky day. Parts came from Andrew. Well...everything except the pipes but that's what I was expecting. Honestly, I'm just happy to have them so that I'm not delayed. Pipes go on last so no big deal. Also, if you'll recall, when I get the bike together it has to go to my paint guy to touch up the frame. He's also going to do the the removal/reinstall of my primary inner/Outer, Rotor/Stator, clutch, chain and adjuster, and my starter. I could have easily done the starter with everything off but since it's attached to the primary why do it twice. I've got a new inner Primary, as soon as I park it in his shop I'll remove the outer and send both to Spacecoast. I've decided not to even mount some of the new chrome. Why take a chance of it getting scratched. In fact, even if I get the exhaust and it somehow miraculously fits, I'll put the old exhaust on also to prevent damage. I'll drop off the wheel hubs Monday to have Bearings pressed in. I did find some Black Oxide Front Hub Bolts that can be torqued to 55 ft. Lbs. I plan to spay zinc or galvanized paint to slow down the rust. I ordered 15 so each time I change fork Oil I'll check them, Replace if necessary. Oil tank and battery Box should be done with powder coating any day now. Also, decided not to install the air ride until bike is out of the paint shop. It would just be in the way. I'm pretty sure I located the two air ride wires (actually 3...one is a dual plug). They were wound up nicely together with a zip tie on them along with the other wires around the battery Box. Plan to send that BDL forward control Mounting plate to my father and have him take it to a machine shop we've always used. So, I've still got plenty to do this weekend. Maybe mount the Hand Controls, Mirrors, Front Turn Signals and Wiring, Head Bolt Covers, and possibly the Rear Rocker Box Cover. I'm starting to feel like I'll beat Winter!
 

82ndAirborne

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Since the Tribal Grips didn't fit I returned them yesterday. Barely made the 90 day return limit. So I checked around and didn't find much that I liked and especially that would match the Tribal Forward Controls and Pegs. VCW had the only acceptable solution for me. They had a set of Knurled Grips that came in Polished and Show Polished. I got the Show Polished, I think around $20 extra. I chose these because I thought they would match the 3 Knurled Rings (sections) of the Tribal pegs. Best I could come up with.
 

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82ndAirborne

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I was looking up the quantity of fork Oil to add to the tubes and came across a video that demonstrates a tool (pump) that's used to suck out the dirty fork Oil rather than drain it. As most of you know already that to change the fork Oil you have to remove the front wheel, pinch bolts, and drain hole Bolts & crush washers. After draining the oil you reverse the process, if necessary replacing Crush Washers. Then you'll apply Loctite and torque everything back to specs. This pump eliminates all that. Simply suck out the old oil, Replace with new, and you're done. I like it, seems to save alot of time and makes the process quick and easy.


 

82ndAirborne

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No...it looks like Metal plugs. I didn't examine the inside before I sent them off (mistake). Anyway, I don't know if those are plugs from Spacecoast or factory plugs and I just can't see how the fluid flows. Can't find a diagram that shows flow either. There could be a pinhole somewhere and I just can't see it.
 

82ndAirborne

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From the pictures in my previous post, I'm pointing at what looks like two plugs. However, I don't know if that's part of the design or something Spacecoast did to seal it wp while the replaced. So, basically I don't know what they are. The problem I'm trying to solve is that I don't see a way (path) for the brake fluid to travel from the reservoir down into the master cylinder. There could be a way, but I can't physically see one. I think the only way to find out is for me to partially fill the reservoir and see if it leaks (travels) to the banjo bolt hole.
 

82ndAirborne

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So the handgrip (brake) problem should be solved. There were round aluminum stickers with tape on top to protect the master cylinder/reservoir holes. They removed the tape but forgot to remove the foil. Should be fine. Made a little progress today before the rain. Installed the rear Rocker box cover (hardest one). I had a spare that I sent to Spacecoast. Now I'll send the one I just removed. Got the front turn signals and wiring installed. Also, almost finished with the rear tire. Hubs are getting Bearings pressed in...then I'll be ready to mount the rear. Hopefully Oil tank and battery Box will be done this week and I can mount them as well. Coming along.
 

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82ndAirborne

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I'm about ready to install the Speedometer. I ordered all new parts except the Tachometer. Someone sent me a link earlier where I could find one but I can't locate it. Anyone know where I can find one?
 

82ndAirborne

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Making progress. Got the Hand Controls all straightened out...including the front Master Cylinder. Just finished hooking up and adjusting the clutch Cable. Also installed the Speedometer. Picked up the tank from my paint guy so I'll put that on this weekend. Rear wheel, hubs and pulley are all polished up and ready to install. However, Oil tank and battery Box is still in for powder coating so the rear wheel will have to wait. Ordered Master Cylinder Rebuild kits for front and back (Curtis), figured they've probably never been torn apart. Also, all the bolts had rust in them and would have probably broken the seals replacing them. Ordered pads from Lyndall and extended Throttle Cables from Barnett. I needed the extension because of the 3" Extended Handlebars. Will probably install the front wheel and possibly front brake line this weekend. So, whenever I get the oil tank and battery Box I can try to fire this thing back up! Machine shop in Kentucky is refabricating the mounting plate for my Rear Brake Forward Control. That should be done Monday. I'll have to have it rechromed on the next shipment to Spacecoast. I'm getting there...most of the rest is simply waiting for stuff to be completed by other shops. My paint guy is a long wait. He's the exclusive painter for Harley of Savannah...I have to wait my turn. I don't expect him to finish until January or February! I don't ride in the Winter anyway so no big deal.
 

Mickmorris

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Making progress. Got the Hand Controls all straightened out...including the front Master Cylinder. Just finished hooking up and adjusting the clutch Cable. Also installed the Speedometer. Picked up the tank from my paint guy so I'll put that on this weekend. Rear wheel, hubs and pulley are all polished up and ready to install. However, Oil tank and battery Box is still in for powder coating so the rear wheel will have to wait. Ordered Master Cylinder Rebuild kits for front and back (Curtis), figured they've probably never been torn apart. Also, all the bolts had rust in them and would have probably broken the seals replacing them. Ordered pads from Lyndall and extended Throttle Cables from Barnett. I needed the extension because of the 3" Extended Handlebars. Will probably install the front wheel and possibly front brake line this weekend. So, whenever I get the oil tank and battery Box I can try to fire this thing back up! Machine shop in Kentucky is refabricating the mounting plate for my Rear Brake Forward Control. That should be done Monday. I'll have to have it rechromed on the next shipment to Spacecoast. I'm getting there...most of the rest is simply waiting for stuff to be completed by other shops. My paint guy is a long wait. He's the exclusive painter for Harley of Savannah...I have to wait my turn. I don't expect him to finish until January or February! I don't ride in the Winter anyway so no big deal.
I’m guessing you are not expecting the blow exhaust? Hopefully you get your money back.
 
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