Rob`s Dyno Service
Contents
1. now plugs the Tec switch harness extensions into the stock switch harnesses Though they don t need to be Dan also solders each connec tion before covering it with the Tec supplied shrink wrap E j ee ree Peete Pek Am a T ke Ls ae Ses e i ne As ear G4 ee SP ee ee ee en Oe After covering the entire harness with the Tec supplied shrink wrap Dan blows a guide string through the bars This string is to take up slack in the harness as it is fed into the bars not to pull the harness through With a guide string taped to the end of the wiring harness Dan coats the harness with a little WD 40 and feeds it into the switch hole while a buddy gently pulls on the guide string 68 Motorcycle Bagger July 2013 Vol 4 No 5 Once both harnesses are through the bars Dan can reassemble the connectors by inserting the pins as per his diagram and popping in the end cap followed by the rubber moisture barrier _ a With the new Tec stainless steel clutch cable routed to the tranny Dan slips a new 0 ring onto the cable and then threads the new cable into the stock end cover It s easy to cross thread this cable so be careful After aligning its tab with the slot in the cover arrow Dan drops in the outer clutch ramp followed by the three stock balls After attaching the stock cable holder onto the end of the new Tec Barnett cable Dan slips the stock inner ramp onto the holde2. the nacelle s switches Dan loosely installs the headlight nacelle using the stock washers and nuts The throttle cables and brake line are routed through the riser opening arrow in the nacelle On the right switch housing D the cables to the new H D handgrip The pull cable goes into the forward hole of the switch housing and in the lower hole arrow 0 n the handgrip iY Dan positions the spotlight assembly onto its stock mounting points and reattaches the two switch harness connectors He then checks that all switches and lights except for the headlight work With a wedge of cardboard between the brake lever and its perch to prevent the lever from breaking the front brake light switch it s in the switch housing Dan installs the master cylinder MotorcycleBagger com After securing all the wiring with wire ties Dan installs the riser cover using the two stock screws and a Phillips screwdriver After aligning the front of both nacelle halves he tightens the nacelle and spotlight nuts using a 1 2 socket a Ce te a The bolt and nut at the front of the riser cover is tightened using a Phillips screw driver and 5 16 wrench This year bike also has a clip that joins both nacelle halves at the front of the nacelle After sliding the headlight trim into place on top of the nacelle and reattaching the head light connector Dan reinstalls the headlight assembly using the stock seven screws an
3. TECH by Tyler Greenblatt INSTALLING APES How to bolt a set of 1 1 2 Carlini 16 apes onto a Road King Here s our 1999 Road King up on Dan s lift ready to receive its new 16 Carlini apes The transmission end cover and exhaust system as well as the handlebars and headlight nacelle have been removed After we removed the seat the battery ground cable was also disconnected FIRST AID O MOST RIDERS A ROAD KING IS THE PERFECTLY SIZED bike Irs long balanced and should be able to handle just about anyone There are exceptions of course such as our Chief Operating Officer Terry O Brien who claims to get mistaken for a Chicago Bears linebacker at airports He might not be quite as ripped and dangerous as the leg endary Brian Urlacher but Terry s definitely a big guy So when he bought his 1999 Road King last year it needed some imme diate improvements to make it work for him First up was a new seat from Mustang and a set of extended forward controls from Accutronix Both of those improved his ride dramatically but the right set of handlebars would be the finishing touch With traditional lines just the right amount of chrome and an overall classy demeanor Terry s Road King would need handlebars that both looked and functioned phenome nally It didn t take him long to decide on Carlini Design s 1 1 2 thick 16 tall Original Apes 300 Original Apes have a total width of 41 spo
4. d a Phillips screwdriver MotorcycleBagger com cycle acces store boyesen Vol 4 No 5 July 2013 Motorcycle Bagger 15 biker barn J amp p frankenstein 16 Motorcycle Bagger July 2013 Vol 4 No 5 tantly the handlebars and stainless braided lines make his bike look like something the real number 54 would want to be seen cruising around on Pd better stop there before I get called into a 5 o clock meeting with number 53 1 2 Once the headlight trim is back in place Dan reinstalls the single stock screw using a Phillips screwdriver He then adjusts the clutch cable as per the H D service manual procedure Pee d 7 i eh ee J B Webs an kea Here s how our finished Road King looks with its new 1 1 2 Carlini 16 apes MB MotorcycleBagger com
5. nd rubber handgrip onto the bars until it reaches the switch housings He then rein After torquing the riser bolts to 100 in Ibs Dan puts some blue Loctite on the two Car lini supplied handlebar setscrews He then installs them into the riser top using a 1 8 Allen W SOURCES CARLINI DESIGN 714 432 9000 CarliniDesign com HARLEY DAVIDSON MOTOR COMPANY 414 343 4056 Harley Davidson com ROB S DYNO SERVICE 978 895 0441 RobsDyno com After he positions the clutch perch so the lever is comfortable for Terry Dan secures the switch housing to the handlebars using the two stock bolts and a T 25 Torx He torques the bolts to 25 35 in Ibs TEC DISTRIBUTING 978 352 4710 TecDistributing com MotorcycleBagger com stalls the clutch lever using just its pivot pin samson Vol 4 No 5 July 2013 Motorcycle Bagger 13 wana ride 14 Motorcycle Bagger July 2013 Vol 4 No 5 R 7 i h k y k 4 an Ds k o q D Once he Once he has installed the Tec Barnett upper front brake line from the brake line spider to the master cylinder following the stock route Dan connects it using a 3 8 12 point wrench and a 7 16 wrench has routed the clutch cable to the left hand lever Dan reassembles the clutch lever setup using all stock parts He then torques the bolts to 60 80 in Ibs tee S an connect S After reconnecting
6. pring on the push cable blue Loctite and a T 40 Torx la EYL UVIZ THE ONLY EFI TOOL YOU LL EVER NEED 1 1 A NOW FULL CONTROL IS AT YOUR FINGERTIPS Power Vision is redefining the world of Harley Davidson EFI flash tuning Whether you are new to fuel injection or a professional tuner Power Vision has you covered Color touch screen easy to use interface pre loaded tunes built in Auto Tune and Quick Tune features eliminate having to use a computer to tune your bike Available for all 2001 2013 EFI model years WATCH THE VIDEOS AND GET INFORMED WWW FLASHYOURHARLEY COM cm With a new Tec supplied crush washer under the head of the stock banjo bolt Dan slips the bolt into the banjo fitting on the new brake line followed by another crush washer After slipping a 1 2 flat washer onto the other riser bolt and then installing it Dan torques both bolts to 35 ft lbs using a 3 4 socket And yes you ll have to turn the front end to get the riser bolts into the top tree TIPS amp TRICKS BEFORE DISASSEMBLING THE switch harness connectors use the Tec supplied diagram to avon ma i He then attaches the line to the stock brake write down which colored wires caliper using a 12 point 3 8 wrench After go where When making the positioning the banjo so the line follows the d Fee fee ISS the connecto rs same route as the stock line Dan torques the locking tab as a reference point bolt to 17 22 f
7. r and rotates it so the cable holder engages the ramp et With the inner ramp positioned over the outer ramp so the balls are in their pockets Dan se cures the outer ramp to the end cover using the stock retaining ring and internal snap ring With a new gasket on the tranny Dan reinstalls the end cover using the stock bolts blue Loctite and a 3 16 Allen He torques the bolts to 100 in Ibs MotorcycleBagger com up to the magnum sizing which isa bit connection to the top triple tree good folks at TEC Distributing the bigger than what he was used to We We re always looking for companies one stop shop for the complicated also went with Harley s polyurethane or products that can make a difficult in aspect of installing apehangers namely riser isolators 56298 03 29 85 so stall easier and help us do it right the the wiring extensions and stainless he would have a factory quality first time That s why we spoke to the braided cables and brake lines We told il i ta te ANON 2 in Dan tightens the cable using a 9 16 wrench l After putting a little WD 40 on them Dan Rese and only one finger since the cable end can Slips the lower part of the H D riser bushing After putting a little WD 40 on them the be broken off if you tighten it too much He set aluminum and neoprene into the rest of the H D riser bushing set aluminum then adds the correct grade and amount of bottom of the top triple tree No
8. rts 8 of pullback and is avail a Fal i i h Wi j 66 e Motorcycle Bagger July 2013 Vol 4 No 5 lt qT 2 T I O gt m Bo O O I a able in 13 16 and 18 heights Carlini also supplied one of its Road King risers HHR 3 175S for 1 1 2 handlebars which is made of billet aluminum and fits under the stock riser cover To keep those big boy bars tracking we went with H D s Magnum Diame ter Get A Grip handgrips 5610009 59 77 With chrome outsides and grippy rubber where your hands go the Get A Grips were de signed for a daily rider where rain mist or crazy drivers require a solid hold on your handlebars Terry quickly warmed ME TOOLS NEEDED e Q tips e Brake clean e Strong string e Solder e Soldering gun e Dremel tool e WD 40 e Blue Loctite e Red Loctite e Cardboard wedge e Flat file e Phillips screwdriver e Snap ring pliers internal e T 25 Torx e T 27 Torx e T 40 Torx e 1 8 Allen e 3 16 Allen e 5 16 Allen e 5 16 wrench e 3 8 wrench 12 point e 7 16 wrench e 9 16 wrench e 1 2 socket e 3 4 socket e Torque wrench in lbs e Torque wrench ft lbs E To remove the handlebar switch Deutsch connec tors from their harnesses Dan uses a pick tool to lift up the little black tab inside the connector that s over a pin before pulling the pin out of the connector MotorcycleBagger com Dan
9. t lbs Since they ll be covered by the switch housings Dan en larged the wiring harness holes in the handlebars until they re 1 2 wide and 3 4 1 long using a Dremel to make it easier to pull the wiring harnesses through the bars To blow the guide string through the bars Dan tapes up all the holes in the bars except the one the string goes in and the one it comes out The pres surized air stream will bring the string right out the other end Before reinstalling the tranny s end cover Dan cleans out all the boltholes in the case with a Q tip and brake clean He also removes all old gasket material Dan had to file down the nub at the riser end of the headlight nacelle s top trim so that it will clear the new Carlini risers E Once Dan has slipped the stock handlebar ground strap over a 1 2 x 2 1 4 coarse threaded bolt he threads the bolt into the Carlini riser using red Loctite and a 3 4 socket 12 Motorcycle Bagger July 2013 Vol 4 No 5 MotorcycleBagger com After positioning the clutch perch onto the Carlini bars and against the switch housing Dan uses the stock bolts and a T 27 Torx to loosely secure it to the bars n After threading the wiring through the slot in the lower riser Dan installs the bars and riser top using the Carlini supplied bolts blue Loctite and a 3 16 Allen Make sure the gap on both sides of the riser are even Dan then pushes the new H D chrome a
10. te you ll and neoprene goes into the top of the top transmission oil have to turn the front end to get them in triple tree EVE TAKEN COMPLICATED OUT OF PROFESSIONAL LEVEL TUNING was 2012 DYNOJET RESEARCH ALL RIGHT RESERVED them what bike we were working on builds and custom dyno tuning we did turned us on to Tec Distributing the size of the bars and they sent us a this handlebar swap at Rob s Dyno Terry in all his publishing executive complete ready to go kit with every RD in Gardener Massachusetts with and Bears linebacker greatness loves thing we needed to get the job done RD mechanic Dan Dan has done many his new setup and actually looks normal Though many know him for engine of these upgrades and he s the guy who on his Road King now More impor After removing the air cleaner cover using a i 5 16 Allen Dan attaches the new cables to After putting wire ties on the clutch and Before he pulled them out from under the gas tank Dan tied a string to each of the old the throttle wheel first the pull cable and throttle cables Dan attaches the Tec stainless throttle cables so he could use the strings to then the push cable which goes into the steel brake line spider to the bottom of the pull the new Tec Barnett stainless steel throt top hole arrow This year bike does not bottom triple tree using the stock hardware tle cables through along the same route use a s
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