Harley FLHS - Hot Rod Bagger

1990 Harley Davidson FLHS

Transformation of a Geezer Glide to a Hot Rod Bagger

I bought a 1990 FLHS Harley Davidson in 1992 with less than 10,000 km. Liked the "space pod" instrumentation. It was pretty much stock when I got it, with these accessories:

Chrome wind deflectors HD 58121-85A
Oil Tank Cover Chrome Trim Rail HD 66050-91
Electra Glide Sport Saddlebag Guard Kit HD 30839-83
Headlight and Spotlight Brim - Custom Chrome

And then I added a few more:

Custom Dresser Solo Saddle with leather skirt HD 52156-91 . Lets you stretch out a little and lowers the seat a little.
FLHS Chrome headlight nacelle HD 67680-91 . That "Road King" look!
FLHS Chrome windshield mount HD 58069-93
Windshield eventually replaced with a Rifle #0.502.00 already cut to eye height.

Here's a list of the mods and repairs I've done to it since, with thanks to Nightrider step by step instructions on increasing power.

Vented crankcase overboard instead of into carb
CV Keihin carburetor modified - slide drilled, idle mix screw unplugged, needle jet replaced with #27094-88, idle jet 45, main 185
Broken Shifter Spring: Transmission shifter shaft and spring replaced. This was done from the tranny side without disturbing the primary.
Rattling gearshifts: After looking at a new Road King, I did the same and cut a 3/4" ID rubber hose, 3/4" wide and slipped it over the metal collar between the gearshifts and the primary case to dampen the rattling.
Ignition switch rewired so lights only came on when switched to "LIGHTS".
Lighting improvement: Spotlights re-wired to work on both hi/lo beam (Harley wires them to work only on low). Headlight replaced with 100w/55 high/low. No relay, no problems.
Tires: Avon Roadrunner AM-20 on the front; Bridgestone Spitfire R11on the rear.

Time to get serious.....

Odyssey 680 battery.
Shaved heads .060". Should raise the compression from 8.5 to 9.4.
Andrews EV27 cam with a new Torrington B138 inner needle bearing and new HD hydraulic lifters at the same time.
Adjustable SE pushrods to deal with the shaved heads.
SuperTrapp Exhaust. 2-1 #828-71453, running 20 discs. Nice tone, little louder than stock - sounds like a Ducati with race exhaust.
Spark Plugs NGK BPR5EIX-11 (iridium).
Zippers High Flow Air Filter Kit, #117-090 replaced the stock backplate and air filter.
Front belt-drive pulley came loose at 55,000 miles, replaced with a new Baker 32T long life pulley, new tranny nut lock plate.
Replace transmission shift lever with "Better Lever". Shaft had some wear and lever was worn, and I really didn't want to pull the primary again and disassemble the transmission to get at the shifter shaft.
Replaced stock ignition with Dynatek 2000i, (D2Ki-5P). This is the in-cone unit, matched to the Dynatek single fire (two trigger) coil, DC6-5.

Zippers Air Cleaner Install

Transmission Shift Lever Install - Better Lever

Dremel Tool with flex attachment and small cutting wheel.

First cut off the lever arm, then split the side of the collar. Needlenose pliers holding the lever stub to one side or the other as it's cut.

Here's the new lever. Stainless, polished, with two hex screws connecting the top and bottom half

Installed, with a blue loctite. Nice and tight.

Close up of shifter shaft (previously replaced) and old lever showing all three cuts made with the Dremel tool. First cut was the (too) high one to cut the lever off. Second was near the base of the bushing. Third was across the bushing.

Rear licence plate bracket HD 4734983A . Modified by angling it forward to match the saddlebags angle instead of straight vertical.

Dynatek D2Ki-5P Install

Removed the old stock ignition sensor plate from the cone. Tried pulling the pins out of the plug and they broke off. Tried working the bundle through the hole in the bottom of the cone but the wire shielding was broken up and after worming the first six inches back up through the hole in the cone I wasn't really saving anything so I just snipped it.

Damn bottom right cone cover bolt was holding the harness, which meant the entire exhaust had to come off to loosen the bolt to let the wire out.

New coil installed in same location as the old one. Left side to front cyl - just the way the spark plug wire worked out, so that is the side the blue trigger wire will go.

Green to Tach (Pink HD)
White to center stud +12 volt on the coil to join the white HD wire.
Blue to left side (-) of coil, front cylinder
Pink to right (-) side of coil, rear cylinder
Violet to the violet VOES wire

Mode DIP switch selection

Switch 1: OFF - normal VOES operation
Switch 2-3: ON & OFF 2-3 combo for normal advance curve
Switch 4-5: OFF & OFF for 6000rpm rev limit
Switch 6: ON for single fire.

Set #1 cyl to TDC. rotate the module plate in the cone clockwise until the LED light just goes off. Static timing is now set, dynamic with a timing light.

Page Updated: Jan 4, 2011