Hot Sportster Frame Mod
For many, one of the most satisfying aspects of being a Harley enthusiast is the ability to work on and build your own bike. The venerable V-Twins we love are comparatively easy to wrench and hop up with basic handtools and the official Factory service manual. There are a plethora of aftermarket companies that manufacture goodies from stock-like benign to the go-fast kind. Oftentimes, the differences between the two are reliability and cost. Generally, the more power you build into the bike, the more money you’ll have to spend to upgrade surrounding parts to withstand the rigors of performance.
As you’re well aware, here at HOT BIKE we like big motors that produce arm-stretching power. Blistering acceleration is one of the great joys of life. With that in mind, we decided to resurrect and resuscitate a blown-up Sportster that’s been neglected and covered in the corner of the stable for too long. After deciding to bring the ’86 XL back from the dead, the first call we made was to motor-performance specialists S&S; Cycle.
After weighing different motor configuration options, we opted for the company’s 89ci setup. In a nutshell, the basics of the motor will be big-bore cylinders and pistons, along with a set of stroker flywheels, all crowned with S&S; heads, roller rockers, and covers. For added get-up-and-go, we received high-lift cams with adjustable pushrods and a Super G carb. Tune in next month when we detail all of the S&S; components for the build.
As per the S&S; technicians, the 89-inch motor is almost 1/2-inch taller than a stock Sportster motor. Due to changes in the frame and chassis over the 18 years of solid-mount Evo XL production, one must mock up the motor in the frame to make sure it will fit. As it turned out, the rear cylinder of our motor was too tall to allow the rocker box to be assembled. Therefore, we had to clearance the frame to allow enough room for final assembly. We contacted Dave Ciesielski of Crash Damage Repair to help us out with the Sportster frame surgery.
Dave’s shop is equipped with a state-of-the-art Scheibner MAX measuring machine as well as a Globaljig to fix bent or misaligned frames. The MAX was designed in Germany, and Dave has the only one in the U.S. Utilizing an opto-electronic, microprocessor-controlled system, it is the most accurate system for measuring motorcycles available. Principal components include a measuring bracket with two electronic measuring cameras, a target unit with infrared illuminated targets, and an integrated microprocessor. The MAX contains factory specifications on more than 1,000 motorcycles and compares measurements with that information. An added bonus of the MAX system is the ability to perform precise measurements without dismantling the motorcycle while being entirely independent from potential front fork damage. It’s a sophisticated tool that performs complex mathematical calculations with ease. The target points in the target bracket follow an arc of a circle around the steering head axis when the front forks are turned. Then the measuring cameras determine and calculate the position of the two targets. An additional laser on the rear of the bracket allows the measurement of the rear frame and the swingarm. Once measured, the results can be seen on a computer monitor and printed out.
Follow along as we take you through the frame modification and subsequent MAX measuring.