The Road King Report Installment 1
By Bandit |

ROAD KING REPORT–Initially I had some questions regarding Road Kings. I wanted to know some about the frame geometry. I perfer a little trail over low speed, parking lot handling. I like to run fast and stable. Next I’m old school. I perfer a bike with minimun extras so I lean toward a carb model over the fuel injection, EFI models.
I immediatly spoke to an expert, Paul from Charlotte, H-D:First as you always say “What year is the damn thing”??????? If it’s a newer model why get rid of the EFI?? The new stuff works good. Harley has new sofware to tune the thing, just out from the dealer show. This will put a big hurt in the Powercomander II and any other after market add on stuff!!!! It’s in the new P&A book for ’03 in the Screamin Chicken (Eagle) section. I like the new Dephi stuff. Also BC Gerolamy has a new dual throat induction throttle body for the Delphi system that is kick ass!!
To take off the system, man it’s lot’s off work. The ECM has all this start up shit it goes thru. checking all the system’s and sensors. Again I have never done this. So to be honest I just don’t know for sure on this one. I can run it by Old Bob tomorrow and see what his thoughts are on both the frame/trees and removing the EFI.
On the frame, my first thought is no. Are you familiar with what they did to the trees? They are not like the old FL stuff at all. The stem is in front of the fork tubes. This makes it a self centering front end. One of the tests they have to do at Talledega on the track is to smack the handle bars hard at 80 MPH++ and see if the damn thing will straighten itself out!!!!
I’ve never thought about doing this so who knows maybe it could be done. Christ you come up some stuff man. Was Jack Daniels involved in all this brain storming??
A week later…
’03 is good year for the Road Queen. The EFI is much better than years past.My question to you is why do you want to loose the EFI?? What are your plans?? Pipes, Big Bore, Stroker kit?? We just did a 103 Stroker kit with cams, heads and a V&H 2-into-one pipe, megaphone, on a ’03 Road Queen for a salesman. He should have used a Thunder Header but most of these clowns want the magazine yuppy chrome look. Shine and billet are in I guess, drives me nut’s!!!!!
You can remove the fuel pump and that shit from the tank. You can put a regular fuel valve in the tank in place of the EFI fuel line. There are two bung’s on the left side of the tank, one is plugged. I did make an adapter for a fuel valve for a Softail EFI bike once. The guy bought these tanks at a swap meet and didn’t know they were for fuel injection.
I think maybe you might just need to change the ECM from EFI to a Carb. ECM. Disconnect the senor’s, eng. temp, crank pos., induction module stuff. Do the tank, install a carb and you might be just be down the road. That way you could leave all the stock wiring and shit in place if you ever wanted to go back to EFI.
On the trees I guess when they went to that style the early top tree was just turned around for that newer style configuration. Don’t know about the setup now. If you did a rotation of the top tree putting the fork tubes forward the bars would be in a different forward location. That would screw up all that headlight cover shit. You might be able to put a complete early FL front end on. Hey maybe even the adjustable sidecar trees. Remember them? The front fork’s are non-air assist now.
I’ll keep plugging away on this “Amazing Raked Road Queen” project for you. I can check out some front end’s and take a better look. Also will try to call tech services at H-D and see what won’t say!!!
–Later, PSD
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SCREAMIN’ EAGLE ROAD KING GETS STROKED
By Bandit |

The Harley-Davidson Custom Vehicle Operations (CVO) team pumps upits wild Screamin’ Eagle Road King for 2003 with the biggestdisplacement engine ever offered in a production Harley-Davidsonmotorcycle a 103 cubic-inch (1690cc) Twin Cam V-Twin tuned to producemore than 100 lb-ft of torque.
Based on the popular FLHRI Road King model, the 2003 CVO Screamin’Eagle Road King features a host of exclusive custom features andaccessories from Harley-Davidson Genuine Motor Accessories. Theheart of the 2003 Screamin’ Eagle Road King, however, is the enginecreated by combining Screamin’ Eagle Big Bore cylinders and a strokerflywheel and rod assembly to the standard Harley-Davidson Twin Cam 88engine. Bore and stroke grows from 3.75 x 4.00 inches to 3.87 x 4.37inches, while displacement is boosted from 88 ci (1450cc) to 103 ci(1690cc). Compression is bumped up slightly, from 8.9:1 to 9.0:1.
The standard EFI system is reprogrammed to match the increaseddisplacement while retaining the crisp throttle response of the stockTwin Cam 88 EFI engine. The drivetrain is reinforced with ahigh-performance hydraulically actuated clutch, a custom oil coolerand a high-strength final drive belt. The result is a motor thatmeets 50-state emissions and sound regulations yet pumps out 100lb.-ft. of arm-stretching V-Twin torque at 3500 rpm, a 20 percentincrease over the stock Twin Cam 88 engine. The engine will beavailable in silver with chrome trim and is fitted with chromeTouring Mufflers.

Motorcycles created by the Harley-Davidson CVO program arelow-volume, custom models produced by a hand-picked team oftechnicians on a special assembly line at the Harley-Davidson plantin York, Pa. Approximately 3,200 examples of the 2003 Screamin’ EagleRoad King will be manufactured. Suggested U.S. retail for theScreaminí Eagle Road King is $27,995 ($28,095 in California).
The FLHRSEI2’s monster motor powers a Road King like no other.Start with the hand-painted Centennial Gold finish with Vivid Blackand Burgundy accents and a gold leaf fuel tank emblem. The frame,swingarm and footboard supports are powder coated in matchingCentennial Gold and the wheels are solid, bright-polished spunaluminum. The bike is dressed up with chrome and billet accessories,including chrome 1.25-inch diameter handlebars, custom billet-stylechrome fuel tank console, chrome billet heel/toe shifter, and StratumCollection chrome billet timer, derby and air cleaner covers withcolor-filled script.
Rider and passenger will enjoy a custom leather seat with chromebuttons, adjustable rider backrest and detachable passengerbackrest. The dark Lexan custom mini wind deflector is detachableand other features include cruise control, a H-D factory securitysystem with siren and a custom indoor storage cover.
The 2003 Screamin’ Eagle Road King delivers the power and theglory that are genuine Harley-Davidson. Features of the 2003 FLHRSEIScreamin’ Eagle Road King include:
Twin Cam 103 TM Powertrain finished in Silver and Chrome
Hand-Painted Centennial Gold with Black & Burgundy Accentsincluding Gold Leaf Fuel Tank Emblem
Color-matched Centennial Gold Powder Coated Frame, Swingarm andFootboard Supports
High Performance Clutch with Hydraulic ActuationChrome Fat 1 inch Diameter Handlebar with Internal Wiring
Chrome Clutch and Brake Master Cylinders, Chrome Switch Housingsand Chrome Hand Levers
Custom Oil Cooler
Custom Oil filter Mount with Internal Thermostat
High Strength Final Drive Belt
Chrome Voltage Regulator
Black 1.4 kw Starter
Coated Braided Stainless Steel Throttle Control
Coated Braided Stainless Steel Front Brake and Clutch Lines
Custom Leather Seat with Chrome Buttons with Detachable PassengerBack Rest and Fully-Adjustable Rider Backrest
Chrome Oil Vent Line with Chrome Fitting
Chrome Oil Line Cover
Chrome Extended Reach Billet Brake Lever
Chrome Billet Heel/Toe Shifters
Chrome Headlamp Bezel
Chrome Lower Triple Tree Cover
Custom Full-Length, Billet-style Fuel Tank Console
Stratum Collection Chrome Billet Timer, Derby and Air CleanerCover with Color-filled Script
Matching Mini Tach Mount with 100th Anniversary Badging.
Polished Spun Aluminum Solid Wheels
Chrome Front and Rear Floating Brake DiscsAnd More
For additional information on the Screamin’ Eagle Road King andHarley-Davidson Genuine Motor Parts and Genuine Motor Accessories,visit the Harley-Davidson Web site at a href=”http://www.harley-davidson.com”>www.harley-davidson.com. To find a dealer near you, call toll free1-800-443-2153 in the U.S.A. or Canada.
Back to Part 1……..
Bad Bones
By Bandit |
A bike in a box, I like the concept. The first thing that pops into my mind is that I’m gonna drop some pretty good coin into a cardboard box the size of a fuckin refrigerator and this is supposed to be my transportation. What kind of parts are lurking in Styrofoam peanuts and bubblewrap?
Well I am not building a motorcycle from a box but my bro is. My friend Bones started with CCI’s Bad Ass ridged chopper kit. It’s a wide-tire rigid frame that sports a Wide Glide front end, five-gallon two-piece tanks and a 100ci RevTech engine with a RevTech 6-speed transmission. Bones isn’t new to American motorcycles. He’s been riding for 35 years and has owned Pans, Shovels, Evolutions and the TwinCam88. He has a nice portfolio of choppers, dynas, dressers, cruisers and customs. He is not a top- notch bike builder or a mechanic or anything, just a man who has been around the block a few times and down two lanes many times. He’s a local club patch holder, someone’s brother, father and husband — a real standup guy in my book.
I’m taking this opportunity to let people know whether this is worth the bread or not. My bro doesn’t have a mechanic’s shop or air tools and lifts, just basic tools and common knowledge, or basic knowledge and common tools. I just want my buddy to have a safe and dependable ride that he has put his time, effort and a little piece of his heart into.
On to Part 2………
Bad Bones (Continued)
By Bandit |
Six burly fuckers lifted the awkward, bulky, cardboard box into the back of the pickup. We stopped at Wal-mart and bought a $100 motorcycle lift. It has a hydraulic jack with a foot pedal pump, locking safety bars and is good to 1,500 pounds. It’s a necessity for the project since it will lift the bike about 18 to 20 inches to allow easier part installation. You can also move the project bike around the floor on the rolling lift.
We backed up to the garage and ripped open the box with pocket knifes. The tires were lying on top of the frame and boxes were nestled inside. Inside those boxes were more boxes and packaged components. We got all the stuff into the garage, sat down, had a beer and stared at the cool RevTech engine crate.
We kept the paperwork no matter what it was with. Slowly we sorted the individual parts in the best order possible down one side of the garage. It was really cool just looking at all those packages, with the chrome-plated goodies and unfinished sheet metal tank that began to take on a paint job in our imaginations.
There is a lot of stuff here — Santee, Accel, Spyke, Doss, Custom Chrome, Jesse James, RevTech, OEM Harley-Davidson, etc…. all in a $11,500 bike kit…
Operation Bad Bones is now in progress.
There aren’t any instructions so a basic knowledge of motorcycles is required.
Bones mounted the fat and skinny Avons on the 40-spokes down Randolph’s Exxon. He bitched a little as he stuffed in the tubes. I drank a couple beers. A person needs to pre-assemble the bike before anything is done, making sure no parts are missing. It may be a kit, but that doesn’t mean everything is going to work together or even be included in the shipment. The parts are not in any specific order so it takes quite of bit of time searching for the correct bolts, washers and locknuts for whatever parts you’re putting together. By Sunday evening, the metal was starting to look like a motorcycle. We encountered a few missing parts in this stage, but they were minor. There were no rear brake shoes, no small screws to hold the stator and no bracket or bolts for the oil tank. Most of this stuff is available at a parts store, but we’re going to see if CCI will stand behind its product. First we’re going to tell the shop where Bones got the kit.
-Smack
Back to Part 1………
HANDLEBAR WIRING FOR THE BRAVE AT HEART
By Bandit |


Your stock Harley has something exposed that you may want to coverup. There’s some ugly issue on your new bike that is screaming foryour attention, and if you are a little crafty, you can work throughthis problem. What’s this nasty problem? Your handle bar controlswiring problem, that’s what. You know those heinous wires that comeclipped to the outside of your handlebars for all to see. Internalizethose wires, and then they will be out of the picture for good. Readon and I’ll explain the basics of hiding those unsightly wires.
You are about to make a commitment that won’t be impossible toreverse, but before you decide to wire your handlebars internally,make sure that you have chosen the correct bar for you and your bike.Stock bars on a Harley are polished stainless steel. They lookgood right when your new bike rolls off the showroom floor, but inabout a year they’ll look duller than a board meeting in Duluth.So you might consider swapping out the stock bars for chrome ones.There are literally a million choices and styles, and prices canrange from $35 to $300 for something exotic. Make sure that you arecomfortable with how the bars feel and look on your bike before youcommit to running the electrical wires inside the reigns. Nothing ismore frustrating than riding all day in the saddle of anuncomfortable bike, especially if it belongs to you.
There is still one other consideration to be addressed before youswap handlebars. Make sure that your clutch cable, brake hose andthrottle cables will still reach if you decide to change out yourbars. There is a fairly large zone where all of your stock hoses andcables will reach when you change your bars. If you choose asignificantly taller or wider handlebar, you’ll be swapping out allof those cables too. If the bars of your dreams are going to involvea full cable swap too, I’d suggest taking your bike to a qualifiedmechanic because of the safety issues associated with that type ofundertaking. (There’s a tech right here on Bikernet that covers all aspects of a highbar transformation.
OK, now you’re ready to tackle the issue at hand, hiding thewires. On a ’96 or older Harley, there are 14 different color-codedwires in the bars, seven on each side. On the ’96 or newer bikesthere’s only 12 wires to deal with, six on each side. Regardless ofthe year, the wires are inside a vinyl loom that has been clipped toyour stock handlebars. On one end of the loom are your switches andcontrols by the grips and at the other end is a connector that plugsinto the rest of your wiring harness.
There are two types of wire loom connectors, ’96 and newer bikeshave a “water-tight” Deutsche style connector. The earlier bikes havea “Mate ‘n Lock” connector. You’ll need to remove the dash and fueltank to get to the connectors on Softails or Dynas, which is probablylocated near the top frame tube. Be careful to drain your tanksbefore you remove them, and yes, gasoline is flammable. Don’tmess with gas in your garage if you don’t have proper ventilation,and certainly never mess with fuel if you have a gas water heater inyour garage. Can you say “Boom?”
Once you’ve found the connectors location and before you un-plugthem, grab a sheet of paper and take some notes. There are twoseparate connectors, one for each side of controls on each bar. Makesure you note which plug went where, and all of the color-coded wireshave a specific location too. Make a diagram of the plug with eachcolor-coded wire tied into their appropriate location in the plug.This step will save you a ton of cussing later on when you don’tremember what went where.

The Deutsche connectors have an orange cap on the end, which youcan pry off with a small screwdriver. Once that cap is removed,you’ll see a plastic clip, which holds the wire terminal. Gently prythe tab away from the connector and pull each wire from theconnector. The earlier “Mate ‘n Lock” connectors have a metal barbbuilt into the wire terminal. You’ll need a small pick to bend thetab back inside the connector, to pull each wire out of theconnector. Bend the tab back to it’s original position and you canreuse the same terminal.
Now it’s almost time to remove your handlebars from the bike.Remove the clutch lever and the brake master cylinder at the clampslocated on each control. Don’t remove the clutch cable or the brakehose from the levers unless you want to trade them out for chromepieces, or just feel like making this a much bigger project for noapparent reason. Make sure to protect your front fender from danglinglevers. The switch housing bolts on the right control hold thethrottle housing and cables. Loosen the cable adjusters on eachcable, and then you can remove the throttle grip. The handlebars cannow be removed along with the switch housings. Remove all the rest ofthe switch housing away from the bike to save your aching back.
Lets get to drillin’. Your new bars may be pre-drilled so you canskip this step. If you need to drill the bars, center punch theappropriate locations under the switch housing locations for thewires to enter and at the center of the bar under the riser for thewires to exit. Start drilling with a smaller bit (Approximately1/4-inch in diameter) to make a pilot hole, and then drill at least a1/2-inch finish diameter hole. Make sure to de-burr the edges insideand outside of each hole with a file or sand paper so they don’tlater cut into the wire insulation. (See the burr tissue test in thehighbar wiring article.) That would be very bad, and you might notknow it until you are stranded at the furthest point from home or acell tower.
Find a piece of stiff wire and run it through the inside of thebars to use as a trail-blazer guide for the rest of the wire loom.Take the end of the single wire and wrap it around the connectors asstreamlined as possible. Get some of that “Strapping” tape you hadleft over from mailing a package last Christmas and wrap it aroundthe bundle of wire, you are about to pull through the bars.Electrical tape will do, but I’ve found that the strapping style oftape does not get snagged inside the bars as easily as the rubbertape, and it seems to grip a little better when you are tugging on it.
Gently pull the wire loom through the bars. At this point youmay want to double check to make sure that you are pulling the rightside switch wires through the right side of the handle bar. Youwon’t be the first to pull them on the wrong side. A simple way toremember which bundle is appropriate for each side is that the bundlewith the Violet wire (Vio-LEFT) is on the left side and the bundlewith the brown wire is on the right side.

Mount the bars in the reverse order described above back on yourmachine. Replace all the wire terminals and the connectors in thesame place that you removed them from (this is where those notes youtook come in handy). Then turn on your ignition switch and make surethat everything functions correctly before you re-assemble the switchhousings. Adjust your throttle cables to allow for maximum throttlewithout binding. When you release the throttle grip, it shouldreturn all the way and not bind if you adjusted it correctly.
Securely mount your fuel tank and dash. Don’t forget the Loctite.Wipe all of your fingerprints off your masterpiece with a soft cottoncloth while you bask in the afterglow of pride and accomplishment.Mission Accomplished.
On the other hand, you might feel like this is a project for aprofessional. Hopefully you can now better appreciate and understandthe skills involved. Internal handlebar wiring is not as simple as itsounds at first glance. As with most anything you modify on yourbike, craftsmanship is king, and if you are not confident in yourabilities shoot yourself and have your widow sell the bike to me.Otherwise you might make a disaster out of what could have been a funproject.
Remember, Keep the rubber side down.
–John Covingtonjohn@surgicalsteeds.com
©2003 John Covington/Surgical-Steeds

Back toSurgical Steeds…
The Pavement Always Wins
By Bandit |

Illustration by Jon Towle
“Aw’ right. How many of you pencil necked geeks think you know how toride a motorcycle safely?” Our instructor, Wayne Jackson, grinned at ussardonically, as he tried to instill in us some degree of learned caution.We were all planted in the drewery classroom for a variety of reasons, some to qualify for the DMVmotorcycle riders license, some to reduce their insurance premiums, some toincrease their skills, some because they know how dangerous riding amotorcycle can be. As for me, I’m trying to scrunch down in my seat as lowas possible.
“I would strongly suggest we close the doors,” Wayne slaps a hammy mitt onthe side of his muscled arm, “the mosquitoes are rabid and vicious,” as hecrushes a fragile bug body. I look cautiously around for West Nile ladenkiller bugs, licking their killer bug lips. Harbor College is located in themidst of a swampy oil drenched bog at the edge of the L.A/Long Beach Harbor.A group of 18 to 20 neophyte and experienced, men and women are awkwardlyseated in a sweltering classroom at Wilmington’s Harbor College. We’veassembled to experience the Motorcycle Training Center’s “Riding and StreetSkills Course.” The training schedule includes two evenings of classroomtraining and two days of riding on their course.
“More than half the riders involved in motorcycle accidents have less than 5months riding experience,” Wayne quotes statistics from the HURT STUDY ofmotorcycle accidents. This 1980 5-year study by Prof. Harry H. Hurt is thebasis for most of the course content.
As for me, I’m starting to have uncomfortable flashbacks to my 1969 Armybasic training. My college education is for naught. What bike ridingexperience I have ran out the door screaming. I’m back to the militarytraining logic of, “There’s the right way, the wrong way and then there isthe Army way.”
My momentary flashback hallucinations are brought suddenly back to thepresent by Wayne’s intense stare in my direction. He has obviously asked mea question while I was back at Viet Nam era Ft. Ord, trying not to be thedumbest recruit ever drafted.
“Sir,” I vainly stumble at toadying to authority.
“Who’s the most vulnerable on the road?” Wanye’s expressionless stare in mydirection caught me like a deer in headlights. I stared back in fearfulincomprehension.
Answering for me, “Šthe motorcyclist.” Wayne continues, “36% ofmotorcycle/car accidents in which the car is going 50MPH, have an impactspeed of 50MPH. What do you think that indicates?” Wayne lightens the drillinstructor demeanor enough to lower my panic response. But I still can’t getmy brain to signal my lips fast enough to speak.
“It means that the car driver didn’t see the motorcyclist, and that the bikerider isn’t sufficiently experienced to avoid the accident.” The whole classbreathes a sigh of relief as one.Wayne Jackson is one of a number of instructors who teach the “MotorcycleRider Course: Riding and Street Skills.” My other instructors included:David Bransky, Tim Thielmans and John Mueller. The $200 course has a varietyof times and locations.
The Motorcycle Training Center, initiated by Red Runyon, opened in 1979. It is one of manysuch schools in California governed by the Calif. Motorcycle Safety Program.The driving course is rigorous but educational. It was a challenge for eventhe most experienced riders. There is constant repeated instruction, but thecourse doesn’t allow for personal, extended instruction. If any studentfails to negotiate the specific exercises or driving procedures, or presentsan issue of safety to self or others, they are asked to leave the course.Students that fail to complete the days’ instruction are allowed to repeatthe course.
I’m sure some of you out there are going to rag on me for supporting such arigid set of bike riding concepts. I agree that in the ‘real world’ thereare a lot of unusual circumstances, unusually capable bike riders andexperiences that may contradict this training. I also feel strongly thatpersonal freedom is a primary issue.
The intent of this course is to give you sufficient survival skills to allowyou to ride another day. They admit that the course will not guarantee yoursurvival. Most will admit that they’ll do whatever they have to do tosurvive. But few would take the position that ignorance is a valuedpossession. Experience is a great teacher, but experience can be a painfullesson.
The course driving tasks are regimented and very specific. Some of thetactics relate to: speed braking, accelerating through a turn, gear shifting,swerving to avoid a road hazard, weaving through cones, negotiating 90 degreeturns, looking through turns, anticipating and reacting to traffic, and muchmore.
My challenge was to listen to directions, that and to not be so damn jerky in mybraking or accelerating, or maybe not being such a jerk. “Squeeze,” Waynewould holler at me above the roar of screaming Yamahas, “just squeeze thefront brake, don’t jerk.” Or did he mean- “Šdon’t, Jerk.”
Somehow on my last day of driving, I managed to take in some of theinstruction offered. My braking and accelerating was smoother. I managed tocalm down enough to understand what was being said. Some were actuallyenjoying the day’s riding. A casual camaraderie lightened the tension.The time had come to show what we had. Tim and John finally ran us throughthe testing phase. There was no joking around now. The peso was on theline. I don’t think you could have forced a dime between our collective buttcheeks, we were all that tense. Each maneuver was viewed silently butcritically. Each rider was evaluated on each element of required procedures.
When we finished, we rolled our bikes into the cargo container, handed inour helmets and stood in line silently, as if awaiting our orders for ‘Nam.I passed! But not without a few of points against meŠ.that damn jerkyaccelerating through a curve, and a couple of other riding indiscretions,but I passed. Two guys had perfect scores. For what it’s worth, I think thisprogram is well worth the time and effort. I can’t imagine anyone whowouldn’t benefit. As a matter of fact, I’m trying to get that belligerenthard-ass, Bandit, to take the experienced riders course. We’ll see what 30+years of wild riding does for him.
The experienced rider course is one day of instruction and driving. The costis $99. Another fun/educational biking experience offered by the MotorcycleTraining Center is the Willow Springs “Streets of Willow” driving course.This is not a school but a chance for bike riders to test their mettle. Probikers will be there to swap stories and give advice. Riders must have 3,000to 5,000 miles of riding experience. Ride your own bike and bring extra gas.Lunch is supplied. For information you may call Leslie at (818) 932-0433 orat www.ccriderlosangeles.com
Belt Handling For Longer Belt Life
By Bandit |

Gates Poly Chain(r) Belts are extremely durable and give long life in aproperly designed drive. However, improper handling of the belt before orduring installation can result in dramatically shortened service life. Thebelt’s tensile cords are designed to carry large loads in tension but notcompression. Compression causes damage to the tensile cords of the belt andcan also lead to adhesion problems. Handling situations that can causecompression in tensile cord include aggressive bending and twisting.Examples of this are:

Crimping The Belt
Crimping of the belt occurs when enough bending pressure is put on thebelt in a small radius so that a permanent “set” is formed in the belt. Thebelt will often take on the outline of a fish head. Crimping damages thetensile cords and will result in premature failure. Do not crimp PolyChain(r) Belts.
Forward Bending The Belt
When handling Poly Chain(r), forward bends (bends that cause the teeth tocome together) should be limited to the following minimum diameter for thegiven belt pitch.
Belt Pitch ————————Diameter (in.)
8mm—————————————3″
11mm (motorcycle applications only)——-4″
14mm————————————–5″
Do not forward bend Poly Chain(r) Belts tighter than the diameters shownabove.
Back Bending The Belt
When handling Poly Chain(r), back bends (bends that spread the teethapart) should be limited to the following minimum diameter for the givenbelt pitch.
Belt Pitch————————- Diameter (in.)
8mm—————————————5″
11mm (motorcycle applications only)—— 8″
14mm————————————-10″
Do not back bend Poly Chain(r) Belts tighter than the diameters shownabove.

Twisting The Belt
Do not twist the belt as shown in the picture. This includes coiling thebelt to make it smaller for packaging.
Belt Installation
Do not use tools to pry the belt onto the application. Sprocket centersshould be adjusted so that the belt can be easily put on by hand.
Back to Belt Drives LTD……..
Bikernet East – The Rolling Chassis
By Bandit |
The competition has changed, expanded. Can home-built choppers fly to Sturgis? Can Jesse James build a chop and actually ride it, with all his tools, mechanics, equipment, lathes, milling machines, and money? Can Billy Lane from Choppers Inc. build a bike by hand while wanton women dance seductively around him daily in him Maimi based studio. Can two crazed fools from Bikernet build two chops in a small San Pedro garage with limited tools and no cash and make it to the Badlands? Another builder has entered the competition, Japanese Jay from the local motorcycle shop, Station 34 in San Pedro. He’s building a rat Shovelhead, I think.
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While we’re damned low on time and still trying to recover property from West Coast Choppers, we’ve decided to get together two running choppers and ride them proudly to Sturgis. We’ve called in all our heavy clients, folks like RevTech, Weerd Bros., and Custom Chrome, Baker, Paughco frames, Headwinds, Harley-Davidson, and put them abreast of our situation and we’re receiving outstanding support as always. Our new goal for the Chop-off 2000, is to race to Sturgis, with back tire fires and heads full of fresh Jack on our custom, hand-built machines. Bandit and I are going back to our roots, building our own scoots, with our own hands, the way we like ’em, fast and simple, no bullshit, no backing out. These will be independence choppers, American-style, no bullshit politics, attitude, downtime, and loss of parts. We just want to ride. As for the vote to see which chopper the world of bikers like best? I’ll still kick Bandit’s sorry ass from here to Lead and back, I’ll have his woman, his whiskey, and he’ll have a view of my back tire all the way. May the best badass win. See you in Sturgis. Saddle up and ride. My Bandit-smashing nightmare is well under way and I’ve employed the assistance of the talented, albeit nuts, Chinaman and the master of horsepower, Wrench. At the moment, I’m way ahead of Bandit. Nothing new there. Billy Lane is hard at it. Jay’s engine is in the frame, and Jesse James, well, he’s in Europe being interviewed by the Pope. In just a few days we’re already working with a rolling chassis. The new horse is sitting on some good-looking chromed Thunderstar wheels from our bros at Harley-Davidson, 21 inches up front and 16 in the back. We chose Performance Machine brakes to stop the monster, once I get to Sturgis. Until then, they’ll get little if any use, since it’s a race. We have the Paughco frame resurrected from the Bandit II, plus a Paughco oil bag. We were going to use the rear axle and oil bag from Bandit’s other chopper, but West Coast Choppers seemed to have somehow misplaced them. The tank will be a Russ Tom Harley-Davidson/Seattle custom stretch. This is where I’ll keep the fuel that Bandit will breathe the fumes from as we streak north. For a front end, I’m going to use a Harley-Davidson narrow glide, which we’re planning to widen with new triple tits. Joel at Headwinds is the man behind the lighthouse-powerful headlamp system, to light my way. I know I can ride from L.A. to Sturgis straight through, because I’ve done it before, but I expect a great deal of whining and crying from the very soft-assed Bandit. The engine will be a beautiful new RevTech 88-inch CAD designed, fire-breathing whip-lashing, get-the-hell-out-of-my-way twin. The whole crew at Bikernet is pumped to test out one of these killer-tech twins as it’s the first RevTech we’ve gotten to try and we’ve got high hopes for her. The engine came complete with a RevTech carb, increased cooling fin surfaces, no head gasket, never-fail O-rings, high-performance, computer-controlled ignition, and it fits the custom frame with no modifications needed—we hope. Just bolt and scream, which is how we like it. And by the way, if you’re wishing you could get one of these fine RevTech monsters in a 100-inch, you can. To transfer all this power to the flypaper-sticky Avon in the back, we’ll be employing a Baker 6-speed tranny. I’ve not yet had the pleasure of running a Baker 6, but Bandit assures me they are as smooth and stout as a bottle of 20-year-old Jack. Can’t wait to marry it to the RevTech and watch them have some of the honeymoon torque sex. And Avon Tires, of course, will be providing the glue to keep me on the road all the way into South Dakota. If you’ve never owned a set of Avons, you’re missing out. |
Bikernet East – An Eagle in the Garage
By Bandit |
Custom Chrome introduces the world’s first rocket-powered Zebra. The power plant of the Great Zebra Northern Steamer for Bikernet Chop-Off 2000 by Special Agent Zebra 05.22.00. The Great Zebra Northern Steamer is to be a biker’s bike. No fantasyland Hollywood bullshit in the way of $80,000 paint jobs or diamond encrusted spokes, no chop-shop hoopla, the Zebra Steamer is going to the root of American bike building, tight, right, fast, and reliable. It’s being built by the rider, with help from Bandit, Wrench, the Chinaman and the torque kings at Casa El Horsepower, in an anonymous garage in San Pedro, California.
These suckers come complete with carb and ignition system. It is literally bolt-in ready when it comes off the truck with any OEM or custom frame that will hold an Evolution. The RevTechs aren’t a cheap amalgamation of aftermarket pieces. The entire system is designed on a CAD (computer assisted design) system, just like the ones used at the big automotive plants. This means you get the latest in engine technology available. Every component is created from new tooling techniques in a state-of-the-art ISO manufacturing plant. But high-tech engineering manufacturing equipment and techniques aren’t any good without great concepts to use them on. Again, Custom Chrome has put its money where its product is and created some revolutionary new thinking in big twins. The RevTech engines use no head or base gaskets. Why? Because they leak and they blow. Instead, CCI uses ultra-high temperature O-rings, which are hard as hell itself. Ignition is computer controlled. They come in 88 and 100-inch displacement. The 88s have 4 1/4 flywheel stroke with a 3 5.8 bore. The 100s boast 4 3/8 stroke and 3 13/16-inch bore. The cases are cut from 356T6 cast aluminum. Every stress point contains added materials for increased strength (read: you don’t walk across the Mojave Desert in August). They also have removable press-in/bolt-in bearing inserts on both the left and right sides of the cases and removable bottom sump-plate permits internal inspection. RevTech’s cylinders have increased fin surface in high-heat areas, for advanced cooling (Fourth of July runs, anyone who rides in New Orleans on the I-10 during rush hour or Miami before or after Christmas day). Steel liners are Perma-locked into the outer aluminum castings. The pistons are cast for controlled expansion, which reduces engine noise and wear.
Special Agent Zebra |

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Bikernet East – Zebra’s Chop Unveiled
By Bandit |
When the dust and metal filings settled, the smoke cleared, and the greasy gang of wrenches at the famous Bikernet Garage sobered up, before us stood a gleaming new chopper, complete and ready to break in, save for a few minor tweaks and a seat.
![]() The Zebra entry for the Bikernet ChopOff 2000 was complete. The Great Northern Steamer, scheduled to blast from the Caribbean shores of South Beach, Miami, all the way to the western Badlands of Sturgis, South Dakota, stood shimmering in the Southern California sunshine. A moment of silence occurred naturally. Then Bandit farted. The Great Northern Steamer is the first complete entry (or virtually so, save for custom seat, a bit more paint, and a few tweaks and adjustments) to come off the steaming chopper assembly line at the Bikernet West garage in San Pedro.
![]() She’s a fast horse, with no bells, no whistles and a low, clean look. This is a true garage chop. Comprised of our favorite parts from our bad-assed vendors who work with us at Bikernet, the Zebra chop should be a joy to ride and not bad on the eyes either. She’ll roll on new Avon rubber, a 21 up front and a 150/16 in the rear, which is as wide as you can go on a stock softy frame without moving swingarms and trannys. We kept her this way because we know a lot of bros don’t have access to zillion-dollar bank accounts and nine-month time periods to re-engineer entire frames. The Zebra chop was purposely built to be an every-man’s chopper—something any of us could build right in our own garage with a bit of determination and hard work. The Avon rubber will be wrapped around newly released Harley-Davidson Thunderstar rims. The engine is a salty RevTech 88 from Custom Chrome and came out of the box humming like a dragon sitting on a cattle prod. I can’t wait to get past the break-in and give that big horse some oats and see what she’ll do.
![]() Expect me and whatever lucky lass I decide to strap on the back to arrive early in Sturgis this year. The tranny is a pussy-smooth Baker 6-speed, known for strength (I’m a bit heavy handed on clutches as Bandit is always pointing out) and high-end gearing. I prefer the left lane. We took the narrow-glide front end off the Bandit II along with the lighthouse-bright Headwinds headlight and slipped it on. I might have Eddie Trotta at Thunder Designs in Ft. Lauderdale, Florida, (where the bike will be received after being shipped from our garage in San Pedro by Ken Gold) throw on a set of wide-glide triple trees. The jury is still out on that one. Eddie and his men will also be in charge of sharp shooting our work, checking for any errors, and handling break-in oversight. All the wiring was done by our resident electrical genius, Bandit, who spent the better part of his three tours in Vietnam keeping the big guns of his heavy cruiser wired tight and barking day and night. The handlebars are Cyclesmith and set flat and low, like the horns on the big bulls that periodically tried to hook my guts out when I rodeoed. Everything hangs off a Ron Paugh special, a Paughco frame, stretched five inches and raked. She’s got a Harley-Davidson battery. The pipes are also from the Bandit II and were initially a ThunderHeader system, the header part, which we sliced off. Now it’s a pair of flashing noise downspouts that make the big RevTech 88 sound like God falling down the stairs when you roll it on. Talk about a sound boner. The call of this big bull will swoon any lass who’s not deaf. The Ride Lo lowering kit actually took the chop a bit too low and we’re planning on having Eddie Trotta’s boys crank it up a few inches so when I load my 220-pound ass on along with a couple hot rod blondes I scoop up from the topless beach in Miami (I’m not kidding, bros, it’s topless, you should visit), the sucker won’t spark all the way to SD. It’s a chain drive up front, rubber in back. I know everyone says the chains look good in the rear, but they buzz the guts out of my ladies and I’d rather have a 20-year-old, six-foot goddess from Spain on back than a sparkly chain any day. I can do more with the Spaniard when I get to where I’m going, if you get my drift. The oil bag was a complete motherfucker and we re-hung it about as many times as a cattle rustler in Kansas who gets caught on your favorite horse with your old lady thrown over the saddle horn and your best rifle in the scabbard. Phil Stadden painted the custom front fender and stock Fat Boy rear fender, which we bobbed considerably. The paint job matches the existing burgundy paint on the Paughco frame, which was one of the parts we got back from West Coast Choppers. Still waiting on the others. I’ll store my gas in a stretched FXR tank that was jerked long by Russ Tom in Seattle.
![]() We have a left mirror, the right seems to be lost in the West Coast Choppers abyss of “missing” parts, so I may have to buy two new mirrors or just run the right side glass. I will take the German Feminine (we’re a bit on the outs at the moment, so we’ll see how this part goes) up to Eddie Trotta’s Thunder Design in Ft. Lauderdale when the Great Northern Steamer gets in and measure for a seat and passenger footpegs. I’m going to try to construct a good-looking seat that seats two comfortably, but retains the very low-profile look of the bike we’ve created. The footpegs will probably sit about an inch behind mine, since the German Feminine was born with enough leg to wade in the deep end of the pool. We may also add a very striking and radical sissybar to keep all of my lovely European sweethearts on the scoot as I cavort about the balmy regions of Miami. At the moment, the highest point on the entire bike sits at about belt loop height and I’d like to keep it that way. But if I have to add a sissybar to keep my ladies from burning their breeches on the twirling rear Avon, then I’ll construct something radical and good looking to throw behind them. If I can get Bandit away from the Jack and women to actually send one out, I’ll probably also throw one of the very handy and well-designed Bandit Dayrolls up front to hump gear and any small tools. Thanks to all the bros at Bikernet West who helped wrench together my entry for the Bikernet Chop-Off 2000. Bandit was the master wrench in charge and spent many a thankless hour, welding naked and screaming in the spooky recesses of the Bikernet garage in San Pedro and deserves a clean clap on the back for a job well done. I’ll keep you posted as I run the new horse through her break-ins down in the 100-degree heat of Little Havana and blow off that new chop smell. Hope all you bros out there are getting your scoots ready for the big run and we look forward to blasting north into the Badlands for some serious partying, eating, drinking, and of course loving the ladies in Sturgis. Now the focus shifts to getting Bandit’s entry completed. His scoot is looking damned good so far and the air wrenches are singing the Bikernet national anthem day and night. Bandit and I will be arriving on (we hope) the 5th, covered in bug guts and bragging rights to start campaigning for the big vote to see which chop the bros chose as the Bikernet Chop of the Year.
![]() Grease up and get your gear, bros, it’s almost time for the big run... May the best badass win. See you in Sturgis. Ride hard, Bikernet East |