One Thing Leads To Another | 1999 Harley Davidson Road Glide Upgrade - Baggers Magazine
Here is the '99 Road Glide. Not a bad looking bike, but it needed a few things.
We used Racine wheels from Renegade Wheels: a 21x3.25-incher at $1,099 on the front and an 18x5.5 at $999 for the rear.
Here's the HHI Bagger Single Disk Conversion kit. This kit will clean up the look of the frontend, complete with FLH lowers legs, a six-piston caliper to fit up to a 13-inch rotor 1-inch axle with flush-mount end caps, and a new brake line. The starting price is around $995, depending on chrome or black legs and what size rotors and calipers you run.
Here's the Renegade 1-inch axle kit with chrome end caps.
We got a set of G3-S Twin shocks ($849.95) from Race Tech to handle the up and down movement in the rear.
For the frontend we used the Race Tech Caddies Gold Valve Cartridge Emulator kits with RT high-performance fork springs to lower the bike. It goes for $259.95.
01. First we picked up the Racine wheels. Once we told the owner, Chuck, what sizes we were running, the guys went to work assembling the Racine wheels and hubs. Here the bearing is getting pressed into the front hub.
02. Next, the hub and sleeve was placed on the wheel and the bolt pattern was lined up with the wheel's bolt holes.
03. Thread locker was used on each of the hub bolts before the install.
04. The two pieces were then bolted together and torqued to Renegade's specs.
05. The same steps went into installing the hub for the rear wheel followed by installing the rear pulley.
06. With new wheels, we needed all-new rubber. The good thing about stopping by Renegade Wheels is that it has tires to fit all its wheels, and can also install tires right away. Chuck had a set of Avon rubber ready to go, and installed a 120/90-21 for the front and a 150/70-18 on the rear.
07. Once the tires were mounted, both were aired up and balanced.
01. We got started on the frontend. First we removed the brake calipers, brake lines, the front fender, and the front wheel. Kazoo then removed the fork tubes from the triple trees so that we could add the Race Tech lowering kit and the HHI lower legs.
02. Here is a look at the H-D dual-brake setup we removed. It will be nice not to see this next to all that new chrome we have planned for the bike.
03. Next, Kazoo drained the fork oil and disassembled the lower legs to get to the damping rods. He also added the new HHI lower legs.
04. Here is the stock damping rod with two holes. For the kit to work, the rod would need to have six 5/16-inch holes drilled for the fluid to flow right.
05. Here is the rod after Kazoo drilled out the extra holes.
06. Next, we wanted to drop the frontend an inch. The shorter top-out spring and rebound spring was placed on the damping rod along with the Emulator. All parts were then slid into the fork tube.
07. The Emulator kit comes with two sets of springs: the yellow handles 64 pounds of spring load and the blue handles 40. The blue set is what is recommended to start with. You don't want it too stiff, making the ride hard. If it is too soft, you can tune the ride from there by swapping out the valve spring.
08. Next, the load spring was installed and Kazoo took a measurement to determine the preload spacer length.
09. With this measurement, Kazoo cut the spacer to size and dropped the spacer into the fork tube.
10. The tubes were then filled with the proper amount of fork oil and the end caps were installed.
11. Once both sides were done, Kazoo slid the tubes back into the triple trees and tightened the pinch bolts to hold the tubes in place, then installed the top cap.
12. The next thing we needed to do was drill out the rear mounting bolt holes on the fender. Kazoo opened the hole size up so that the fender could be rolled forward and clear the tire without rubbing on the underside of the fender.
13. The fender was placed back on the bike to get ready for the Renegade wheel and HHI brake.
14. Both wheels received a set of 13-inch HHI floating rotors to match the Racine wheels.
15. Here is the Hidden Axle Kit. Before Kazoo could install the wheel, he needed to install the captive nut.
16. The splined cap with the internal threads is called the captive nut; this was installed into the left side lower leg and will be where the axle threads into.
01. Next, the wheel was placed on the bike, and the axle was slid through the wheel and threaded into the captive nut.
02. Kazoo torqued the axle to 39 lb-ft, then installed the lower pinch bolts.
03. With the wheel in place, Kazoo installed the new six-piston HHI caliper to the left side lower leg.
04. The kit comes with all the fittings and a new brake line that replaces a stock-length line. Custom sizes can be ordered if needed.
05. For this install we also needed to replace the 9/16 bore master cylinder with a 5/8 bore master due to going to a single caliper. Once the line was connected, Kazoo bled the brake line of all air bubbles.
06. Moving to the back of the bike, the rear Racine wheel was tucked in the swingarm along with the new brake caliper bracket. Kazoo took advantage of having the bike apart to upgrade the rear brake as well.
07. Here is the HHI four-piston rear caliper and brake bracket.
08. Once the caliper was in place, Kazoo connected the brake line and bled the air from the line.
09. Looking for a better ride from the back of the bike, we also replaced the stock H-D 13.5-inch shocks with a set of 12.5-inch Race Tech Custom G3-S Shocks. The Internal Floating Piston design allows the shock to give performance handling and plush comfort in a compact, reservoir-free shock body.
01. There you have it. We installed the bags back on the bike along with the seat and exhaust pipe. Kazoo tested the brake to make sure there was a good bite down on the rotors. He took it out for a testride.
02. Once the caliper was in place, Kazoo connected the brake line and bled the air from the line.
03. The old iron is really starting to look good, almost like a new bike. We added wheels from Renegade Wheels, fork legs and brakes from Hawg Halters, and suspension from Race Tech. Check back as we are thinking about exhaust and paint for future stories. Let us know what you think about it and any ideas you may have.
'99 Road Glide Upgrade
If you didn't happen to catch last month's issue then shame on you. Ok, maybe your subscription was lost in the mail; if so we'll let you off the hook this time. We did an install with Custom Cycle Engineering on a '99 Road Glide with some handling issues. We installed the Swingarm Retrofit Conversion Kit and boy did it make a big difference to the bike and the way it handled. The bike is owned by Kazoo, a tech at Freedom Cycles in Orange, California. He got his hands on the bike with the hopes that all he would need to do was give it a fresh new look. The 10-year-old Road Glide has just more than 60,000 miles on it and is stock for the most part. It runs strong and was a good deal; we just need to address a few small things.
So like so many projects, once we got started working on one end of the bike, we found something else in need of attention, and one thing led to another. Kazoo made up his mind to jump in with a set of Renegade wheels. One of the newest and coolest wheels is the Racine with a starting price of just $899.95 each, depending on the size and style of cut. This is a great-looking wheel and a good price for the guy hoping to change the look of his bike on a tight budget.
Well this brought up the idea to also look into some better brakes, and HHI happens to have really good brakes and a new kit that cleans up one side of the frontend with a single-sided rotor setup. This would show off more of the wheel, making a big difference in the bike's looks. Since we needed to take the frontend apart to swap out the lower legs to do the HHI kit, we figured we may as well work on the suspension and lower the bike at the same time, or at least bring it back to stock height to accommodate the taller wheels from Renegade. We accomplished this with a set of Race Tech G3-S shocks in the back for true comfort on the bumpiest of roads and the Caddies Gold Valve Cartridge Emulator kits with RT high-performance fork springs to lower the bike but still have good suspension.
All in all we wanted a fresh new look, better brakes, and solid handling. It may sound like a lot to do all at once, but we wanted to save time by not having to remove the same parts over and over again.
Hawg Halters Inc.
(714) 628-0049 | freedomcyclesoc.com
Hawg Halters Inc.
(877) 442-5837 | hawghalters.com
(951) 279-6655 | racetech.com
(714) 998-7297 | renegadewheels.com