OutToWinPAHC's, HD Rigid Bobber Evo journal

[OutToWinPAHC]

My Rigid bobber

. 1996 Harley evo engine 1340CC fresh built
. Paugcho Rigid Straight leg frame powder coated gold
· 4" over Springer Front End
· 4-Speed ratchet top Transmission
· Kick and Electric start
· 3" BDL Open Belt Drive Primary
· remote oil filter set up
· Paugho upswept exhaust
· Z-ape bars with Flyrite white grips
· 16" wheels with 40 count spokes and new wide white tires
· stretched sportster tank with custom paint
· Biltwell solo seat pan with handmade custom cover and LaRosa billet seat shocks
· Rigid Solo bag
· Mini-speedo
Upgrade mods

- BDL clutch 35% more surface then stock
- Dynatek Dyna 2ki Ignition module
- Crane Cams High Intensity single fire coil
- S&S Super E carb
- S&S Intake manifold
- K&N filter
- S&S oil pump
- Crane Cams upgraded oil pump springs

And I think I am going to install a mild street cam on it to liven it up.

The Purchase
Purchased the bike on eBay April 2010, for a hell of a steal, but it was needing some work. From the photos I knew that to be legal in PA I was going to have to add a few things to the bike, such as turn signals, horn, high beam, and a rear fender.

Auction photo


Hands on
I got the bike and fixed the one known issue. The bike was running like crap, so I did a clean and rough tune of the carb and took it up to Larrys hotrods and Harley’s. They rebuilt the car, and rejetted it and dyno tuned it. Other issues were the kickstand stop was broken, the seat mounts were not right, and the wiring was hacky. The kickstand stop was repaired and welded at Larrys also.

A few days later the bike kept stalling out on me, took a few days of poking to find out that it was a bad ignition coil. I also found that the center frame gusset was cracked. I did a temp fix on this by bolting a 1/4 inch steel plate on to it.

I ordered some parts to fix the ignition issue and electrical. I used a Honda CBRF4i signal / horn switch, solid state flasher, and grips with signals in them dot approved for front and rear use. I ran the wiring through the frame and handlebars. I also mounted up an ebay horn for a sportster. I need to install a few inline fuses because as of now I only have one main Ignition fuse. I am also on the hunt for an old school short smooth fender, but I got a 6 inch flat fender that I am going to rig up until I can find a decently priced vintage one.

Also changed the oil and gear oil Amsoil 20/50 in engine, GL4 75/90 in trans, gray oil filter

Other problems found
-Front caliper installed bleeder down, forks are identical side to side so I am pulling the wheel and flipping it so that the caliper is properly installed.
-Caliper bolt missing, new ordered
-Trans is a drippy hooker. 4 speeds are known for leaks, and this one leaks, over the winter I will fix it. (gasket and seal kit)
- loose bolts here and there


Pics I snapped last night working on the signals and wiring.
Needs one hell of a good cleaning when I am done
Check out the TST Angry piston logos
Fender is just sitting on the tire, needs trimming and then fitmet. Grips with built in signals on. Horn mounted next to petcock (need to heat shrink the wires.

[DelayedZ]

Haha took me a second to find the angry piston lol, this looks like a fun project.

[JDMTyler3326]

I like the gold frame. Awesome project.

[OutToWinPAHC]

Hoping to get the wiring finished tomorrow, I need to install and hide the flasher, some inline fuses and wiring. Then once the weather clears I am going to see how it run with a new coil. If all is well I am going to rig up the fender until I can get a shorty smooth 16 inch vintage job. Just love the old school look, even though I look so out of place on the bike... I need a beard, a bigger gut, and some leather.

[Vr-4-Life]

dont forget the assless chaps...

[OutToWinPAHC]

I gotta keep my pant leg rolled up sucked into the belt.... no chaps

[OutToWinPAHC]

So she still aint running right I thought it was the coil, nope I got spark. Got compression, no vacuum leaks, got fuel..... So I said screw it and ripped off the $450 carb and took it apart..... mind you I had it cleaned, rejetted, and tuned 2 weeks ago..... all sorts of issues, O rings cracked, dirt galore, gasket cracks, clogged up holes and a cracked diaphram. The bad news is when I pulled the accelerator pump 2 small ball bearings and a tiny spring popped out grrrr......

Anyhow I ordered a master rebuild kit with damn near everything for 80 bucks, gonna rebuild her properly this time before tuning...... which I am not paying for, the should have cleaned / repair it at the time of jetting and tuning.

[motorvated]

I want a bobber in the worst way. This is a great start. I think the tank needs to be remounted, or that could just be my taste. I think the rear of the tank should be lower, so it follows the lines of the frame better. Otherwise, an awesome base!

[OutToWinPAHC]

I was looking at that today. But the only way is to drill the frame... well I could drill it, and then weld in a spacer for integrity, but I have a lot of wires hiddent in there too. I may just do a peanut tank one day after I get her running right.

[OutToWinPAHC]

Oh I broke down the carb and soaked all the parts in seafoam, it was really dirty. I also ordered a master rebuild kit, which I am going to myself then rough tune it and take it back down to Larrys.

[motorvated]

Yea I was thinking a new tank.

[OutToWinPAHC]

Rebuilt the carb. Got it running and rough tuned it, took it out in the neighborhood and tuned it as I rode it and adjusted the AF. Then washed it, buddy stopped by and we took a ride up state road then I broke down in Bensalem again. I had it towed back to Larrys and the owner came down and open the shop and let me put it inside (Nice guy to do that on a Sunday). He is going to charge, retune it, then check the fueling, it almost seems as if its runing out of fuel. He thinks it may be vapor locking to to the tank not being vented. They are also going to check to make sure the ignition module isnt dying out. But I am pretty damn sure it running out of fuel with gas in the tank.

[OutToWinPAHC]

Diagnosed....

The ignition module is bad, after it warmed up it would loose it path to ground slowly causing the 12-14 volts at the coil drop until it stalled which was about 3 volts. Cost to repair...... Parts $250.00, Labor $125 which is module replacement, running the wires through the frame, timing, retuning the carb on the dyno.

Old ignition was crane cams, new is Dynatec Dyna2ki


Next.... proper old school fender
Then... fixing the trans leak
Then... Andrews Camshaft

[OutToWinPAHC]

Rear fender is on, bikes up and running great, new ignition feels good.... but shes a back breaker.

[motorvated]

Looks good man. Not a fan of ape hangers though. I like the real low bars that are pretty much just a straight bar. Coming along well though.

[Got Insulin?]

Need moar suicide shifter. Otherwise, it looks dope.

[OutToWinPAHC]

Hah screw that, It hard enough with that old 4 speed. Thinking about getting some por 15 engine paint and rebrushing the engine. Trans is a mess, leaves it mark all over. I think I am going to put a 5 speed on her.

[fear_no_evo]

saw this thing on craigslist

[OutToWinPAHC]

Yep, I was offered 8.5K for it the other night, but I wouldn't mind something with a softtail. I got this thing uber cheap for what it has. So if someone wants to trade a decent softtail model for it I'm game. 4 gears, hardtail is cool for around town, but the highway is scary. But if not I'm gonna just keep her and put a 6 speed on her and sell the 4 speed, and maybe do some other seat springs cause these ones are too stiff.

[Nick Merrone]

Originally Posted by OutToWinPAHC

Yep, I was offered 8.5K for it the other night, but I wouldn't mind something with a softtail. I got this thing uber cheap for what it has. So if someone wants to trade a decent softtail model for it I'm game. 4 gears, hardtail is cool for around town, but the highway is scary. But if not I'm gonna just keep her and put a 6 speed on her and sell the 4 speed, and maybe do some other seat springs cause these ones are too stiff.

my dad has a dope ass bike for sale for 5k