Upgrade Suspensions - Sweet Tracker | Stock Sportster to Dirt Track Racer

12. Tony runs a tight ship and makes sure everything is in top-notch condition before it’s installed. Here, he turns the new springs on a wire wheel to make sure there are no high spots that could inhibit performance. They were then washed and ready to be installed.

12. Tony runs a tight ship and makes sure everything is in top-notch condition before it

With the front and rear wheels coming off, it was the right time to upgrade the front and rear suspension. Race Tech’s FLEK S3590 Fork Suspension Kit ($259.99) with Gold Valve Emulator technology emulates a cartridge style suspension setup. First of all, Race Tech drills more holes in the stock damping rod to flow more fork oil, which ultimately aids in better, more controlled oil flow and damping. The holes on the gold valves are also larger than stock to flow more oil in more of an unobstructed manner. The tunable gold valves sit atop the modified-stock damping rods inside the fork tubes and are held in place with the main springs. Once the fork oil passes through the modified damping rod, it reaches the Emulator’s bypass valve in the check plate, which provides a firmer, more controlled feel for the rider when encountering bumps. Since the gold valves are adjustable, riders can make adjustments by adding different springs to the gold valves to better fit rider preference and riding conditions. Race Tech offers multiple front and rear suspension kits for all Harley models.

13. Next, Tony measured how long the spacers needed to be and cut them accordingly.

13. Next, Tony measured how long the spacers needed to be and cut them accordingly.

Since I grew up around dirt bikes, I’ve always had a place in my heart for Öhlins shocks, and its unmistakable gold piggyback reservoirs. Öhlins is based in Sweden with many distributors around the world manufacturing shocks for multiple powersports industries. The company is making a push to offer more products for the American V-twin market and offers shocks for all the twin-shock Harleys (excluding Softails). With that said, the HD 141 S36PL shocks ($909) were the perfect fit for the style I’m after. S=Single tube, 36=Piston diameter, P=Gas-type with piggyback reservoir, and L=Adjustable length. Not only is the preload adjustable, but also the shock height can be adjusted to boot. The S36PL shocks are lightweight, brilliantly machined from aluminum, and are very easy on the eyes.

That about wraps it up for this installment of the Sweet Tracker. I have to thank the Wheel Works crew (Dave, Gary, Mat, and Adam) for helping me get the project multiple steps closer to getting it done. Stay up to date with the build process via hotbikeweb.com, facebook.com/hotbike, and twitter.com/hotbikemagazine. Also, there will be more in-depth build articles of the Sweet Tracker in future HOT BIKE issues and you don’t want to miss out, because as Ricky Bobby says, “If you’re not first, you’re last!” HB

14. Tony did a thorough test fit in both fork tubes to make sure everything lined up and fit just right. Now it was time for final assembly. Tony added Race Tech’s Ultra Slick fork oil with the slider completely collapsed.
14. Tony did a thorough test fit in both fork tubes to make sure everything lined up and
15. Then the Emulators were installed and the excess fork oil was removed via a fluid evacuation tool.
15. Then the Emulators were installed and the excess fork oil was removed via a fluid ev
16. Tony popped the springs, spacers, and washers in the tubes and installation was almost complete.
16. Tony popped the springs, spacers, and washers in the tubes and installation was almos

17. Just a quick turn of the fork tube caps and Tony checked the tubes by compressing them on the ground to make sure there was no drag or bind to make sure the Emulators were properly seated. After that, it was time to take the new Race Tech revamped forks home and get them back on the bike and ready for Wheel Works.
17. Just a quick turn of the fork tube caps and Tony checked the tubes by compressing the
18. With the forks completed, and the triple trees back from being powdercoated satin black to match the fork lowers, I reinstalled the entire frontend in order to wheel the bike on over to Wheel Works for the 19-inch front-to-rear wheel conversion, and the belt-to-chain conversion.
18. With the forks completed, and the triple trees back from being powdercoated satin bla
19. Here’s the front 13-spoke wheel I scored from Craigslist for $50. Also pictured is the Baker wheel and trans sprockets, the chain, and spacer for the trans sprocket. Baker also sent wheel spacer blocks to mimic the stock rear wheel width; however, they were too small so Wheel Works had some new ones machined that fit like a glove. The spacer blocks were drilled and each side of the wheel hubs had to be re-drilled and tapped to fit the new spacer blocks and new hardware.
19. Here’s the front 13-spoke wheel I scored from Craigslist for $50. Also pictured is th

20. The sprocket side spacer was attached and the wheel sprocket was mocked up to check for fitment of the chain drive with the new wheel setup.
20. The sprocket side spacer was attached and the wheel sprocket was mocked up to check f
21. Off came the stock trans pulley and spacer…
22. …On went the new trans sprocket.

23. The chain was looped around the trans sprocket and was ready for the wheel to be installed so it could fit around the wheel sprocket.
23. The chain was looped around the trans sprocket and was ready for the wheel to be ins
24. But first, the Öhlins S36PL shocks were to be installed. As mentioned earlier, S36PL is a high-tech, high-quality racing style shock that allows users to adjust preload, compression, and rebound.
24. But first, the Öhlins S36PL shocks were to be installed. As mentioned earlier, S36PL
25. The shocks come with sleeves that mount inside each eyelet on the top and bottom of each shock, and washers that mount on the outsides of each shock. The amount of washers needed vary by application, but in this case two washers per bolt were used for each shock (eight total). The sleeve was placed inside the eyelet, then a washer, the bolt, and the last washer.
25. The shocks come with sleeves that mount inside each eyelet on the top and bottom of e

26. The wheel and sprocket were installed and the chain was attached to the sprocket. Then the shocks were attached one at a time starting with the right side. Once the top shock bolt was tightened down…
26. The wheel and sprocket were installed and the chain was attached to the sprocket. The
27. …The bottom bolt with washers and sleeve were then tightened down. The left side shock installation was repeated and the shock, wheel, chain drive mock-up was complete.
27. …The bottom bolt with washers and sleeve were then tightened down. The left side sho
28. Now, it was time for some fresh gold powdercoat for the wheels. I headed over to HB Performance Coatings in Anaheim, California to have the wheels powdercoated gold. For an in-depth video of the powdercoating process, check out hotbikeweb.com.
28. Now, it was time for some fresh gold powdercoat for the wheels. I headed over to HB

29. With the wheels powdercoated, and the sprocket polished to a mirror shine, it was time for final installation of all the parts at Wheel Works.
29. With the wheels powdercoated, and the sprocket polished to a mirror shine, it was ti
30. Mat started by installing the Lowbrow Customs Fork Gaiters to the frontend. We saved this step for final assembly since the Gaiters are tightened down with zip-ties.
30. Mat started by installing the Lowbrow Customs Fork Gaiters to the frontend. We saved
31. Then he mounted the Dunlop CD5 dirt track tires to the freshly coated wheels, and applied the gold Dunlop decals. Next up, the spacer blocks were attached to both sides of the new 19-inch rear wheel, and then the sprocket and rotor was reattached to the rear, and the rotor reattached to the front. Lastly, the wheels were balanced and ready to roll.
31. Then he mounted the Dunlop CD5 dirt track tires to the freshly coated wheels, and ap

32. Up front the new wheel slid in place like a glove.
33. Same went for the new rear wheel. Once the wheel was in place, the chain was hooked up to the sprocket and everything was tightened down. Installation of the rear wheel conversion, the chain conversion, and the front and rear suspension upgrade was now complete.
33. Same went for the new rear wheel. Once the wheel was in place, the chain was hooked
34. Here’s a shot of the converted product. The dual 19s provide the proper dirt track racer look and the black and gold theme is just how I want it. I can’t wait to move on to phase two of the Sweet Tracker build, whatever that may be. Stay tuned.
34. Here’s a shot of the converted product. The dual 19s provide the proper dirt track r