Making progress. I did a mild rebuild of the top end - hone cylinders, new rings, lapped the valves, all new gaskets and seals. Also re-sealed everything on and under the primary cover, as there was evidence of an oil leak.

Installed a Mikuni HSR 42 carb (it had fuel injection) and an Arlen Ness "Big Sucker" intake. A stainless 2 into 1 exhaust is waiting in the wings. The 2007 and later Evo engines have Buell heads, so they should breath pretty good. I'm thinking 90 to 100 hp and about 80 ft-lb of torque with the mods I've done. Should be fun.

Front suspension is done. I replaced the 21-in. hoop with a 19-in. and installed a fatter tire - should make for quicker turn-in and better grip. I replaced the fork oil with 15-weight to increase dampening, and replaced the fork springs with a heavier set (Progressive), installed fork boots, re-packed the steering head bearings, and installed a fork brace.

Next is the rear suspension. New, taller rear shocks are on their way. Will replace the swingarm bearings. For now I'm going to stick with the original rear wheel, but installing a slightly narrower tire. The fender supports still have to come off and I still have to fabricate a shorty rear fender. There will be no front fender. Rear-sets (sport bike style foot controls) are on the way.

Aside from all that I still have to install the ignition system and completely wire the bike, pressure check the gas and oil tanks, install oil lines, paint everything, and a lot of other odds and ends. Also have to fabricate a seat mounting bracket.

Really looking good Axel, weird I was just looking at Black Eagles winter project thread and was thinking about your project.

Wow, that's really coming along! Looking good.

Hopefully it will be done in the next few months. Not as practical as other bikes, but it should be fun. It won't be any good in the rain and there's no room for luggage or even a passenger - but that's not the point.

axel wrote:Hopefully it will be done in the next few months. Not as practical as other bikes, but it should be fun. It won't be any good in the rain and there's no room for luggage or even a passenger - but that's not the point.

HAH, hardly ever rains in the southwest. Besides 3/4ths of the fun in a project like that is the process of getting to the initial roll out when its done.

I'm a sucker for Sportys and this looks like it's gonna be a. Great one!


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I'm currently in Year 2 of my 6-cyl. flat-tracker build. It's a long road to be sure.
Doesn't help that I only get a few hours every few weeks to work on it.

I think I'm on year 12 of a super single cafe XR670 project. Was doing great until guns got in the way.

Guess I'm on the fast track with this one. Good thing about the Sporty is that both factory and aftermarket parts are available and easy to get. I also have both a Harley dealership and custom shop within ten minutes.

Also taking the rest of the year off since I have to burn off some vacation and comp time before January 1st.

axel wrote:
Also taking the rest of the year off since I have to burn off some vacation and comp time before January 1st.

Or? What happens if you don't?

rascally wrote:

axel wrote:
Also taking the rest of the year off since I have to burn off some vacation and comp time before January 1st.

Or? What happens if you don't?

Use it or lose it.

axel wrote:

rascally wrote:

axel wrote:
Also taking the rest of the year off since I have to burn off some vacation and comp time before January 1st.

Or? What happens if you don't?

Use it or lose it.

Hmm...that kind of sucks. At least when I was military I could (and did) save up 3 years of paid vacation time before losing any of it.

rascally wrote:

axel wrote:

rascally wrote:

axel wrote:
Also taking the rest of the year off since I have to burn off some vacation and comp time before January 1st.

Or? What happens if you don't?

Use it or lose it.

Hmm...that kind of sucks. At least when I was military I could (and did) save up 3 years of paid vacation time before losing any of it.

When I was in the military it was 60 days (2 years). Anyway, I could probably talk the CEO into letting me carry it over to next year, but I wanted to take the time off anyway (I work directly for him, and have made a lot of money for the company this year).