In Part 1 of our project bike build, we outfit HOG s Project RUSHMORE for around-town cruising and long-distance touring.

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1 PROJECT BIKE YEAR 1

2 PROJECT BIKE Project RUSHMORE In Part 1 of our project bike build, we outfit HOG s Project RUSHMORE for around-town cruising and long-distance touring. By MATT KING Photography by MICHAEL LICHTER Our 2014 Street Glide Special is an amazing bike right off the showroom floor. Featuring all the updates of Project RUSHMORE, including enhanced power and handling, improved aerodynamics, intuitive ergonomics, and, of course, a kickass Boom! Box 6.5GT audio system with built-in touchscreen navigation, it s a versatile, all-around motorcycle. But if there s one downside to the Street Glide s stripped-down character, it s the lack of full luggage and passenger amenities. An Electra Glide Ultra Classic might be overkill for some people, but there s no arguing that for riding anywhere, anytime, in any weather, it s a pretty sweet setup. So we set out to add a few key accessories to enhance our bike s comfort and convenience for long-distance riding. Plus, who can resist customizing a new bike? Part 1 of our project bike series starts with Harley-Davidson s 4-Point Docking Hardware Kit. This ingenious system allows quick installation of a variety of backrests, luggage racks, or a Tour-Pak without any tools. For a short solo cruise, the docking system easily retains the stripped-down look the Street Glide is famous for, but when it s time to load up for the long haul, in seconds we can reconfigure the bike with several different luggage options. It s the best of both worlds. For our HOG project bike, we selected a combination of the Air Wing Luggage Rack and backrest plus a chopped Tour-Pak. The backrest alone is great when you re riding two-up, and if you need a little more luggage capacity than the saddlebags can hold, just snap on the rack. It s also great for gear that s too bulky to fit into a Tour-Pak. The Chopped Tour-Pak is a terrific option for trips when you want a little more security for your gear, plus the backrest support it provides adds just a little more comfort for your passenger. With a 3,285ci capacity and 10.7-inch height (compared to 4,290ci and 13.7 inches for the COMBO 1: CHOPPED TOUR-PAK 50 V O LU M E 25 PART PART NO. Color-Matched Chopped Tour-Pak Amber Whiskey Detachable Two-Up Tour-Pak Mounting Rack Tour-Pak Backrest Pad Fitted Tour-Pak Lining Chopped Premium Travel-Pak for Chopped Tour-Pak DST $ $ $ $79.95 $ V O LU M E 25 PRICE

3 King Tour-Pak), it s not quite as luxurious as the combo on an Ultra, but the sleeker dimensions are a great fit for the Street Glide s look. In addition to the luggage options, we outfitted our project bike with a few accessories to enhance its ride and looks, starting with a set of highway pegs. If you haven t tried a set, they re great for stretching the legs out on a long haul. We also added a Three-Pocket Fairing Pouch, which is handy on any bat wing fairing-style bike for stashing sunglasses, wallet, or our favorite snack a pack of Twizzlers. We capped off the first round of HOG s Project RUSHMORE mods with matching accessory grips and a plush Road Zeppelin Air Adjustable Touring Seat. We re ready to hit the road with our project bike, and we ll be buzzing the highways and hitting H.O.G. rallies for the rest of the year. COMBO 2: BACKREST AND LUGGAGE RACK PART PART NO. PRICE Air Wing Sissy Bar Upright Chrome $ Air Wing Luggage Rack Chrome $ Passenger Backrest Pad Air Wing $99.95 LED Light Kit for Air Wing Luggage $69.95 Rack Red Lens Light Kit Wiring Harness $14.95 Premium Touring Luggage System $ ADDITIONAL PARTS (BOTH COMBOS) PART PART NO. PRICE 4-Point Docking Hardware Kit $ Three-Pocket Fairing Pouch $ Hidden Antenna Kit $69.95 (required with QD luggage rack) Road Zeppelin Low-Profile Air $ Adjustable Seat Hand Grips Get-A-Grip, Chrome $79.95 Adjustable Highway Peg Mounts A $ Short, Chrome Highway Pegs Streamliner $ Shifter Pegs Streamliner (2 required) $59.90 The prices appearing here are the manufacturer s suggested retail prices. Actual retail prices may vary. ON THE WEB Visit hog.com/projectbike to see the latest behind-the-scenes videos: See additional HOG project bike configurations and watch Harley-Davidson Chief Stylist Ray Drea (pictured) perform pinstriping wizardry. HOG MAGAZINE VOLUME 25 52

4 PROJECT BIKE Suck, Squeeze, Bang, Blow Part 2: Installing a Stage 4 Kit and High-Flow Exhaust System on HOG s Project RUSHMORE. By MATT KING Photography by MATT KING In simple terms, a Harley-Davidson V-twin engine is a big air pump. Air enters through the air filter, is mixed with fuel in the intake manifold, compressed in the cylinders, ignited by the spark plugs, and forced out through the exhaust pipes. The resulting controlled explosion spins the crankshaft, transferring power to the rear wheel through the clutch, primary drive, and transmission. So it stands to reason that the more air you can suck into the cylinders, the harder you can squeeze it; and the faster you can blow it out, the more bang the engine will deliver. That s what we set out to achieve by installing a Screamin Eagle Street Performance Big Bore Stage 4 Kit and High-Flow Exhaust System on our Project RUSHMORE project bike. Although the High Output Twin Cam 103 engine in our 2014 Street Glide Special already produces a nice bump in power compared to previous year s models, the Screamin Eagle parts take it to the limit of 50-state street-legal performance with factory-engineered parts that maintain the bike s limited 24-month factory warranty. The Screamin Eagle Stage 4 Kit amps up the internal combustion action with 10.5:1 high-compression pistons, CNC-ported cylinder heads, high-performance camshafts, and a larger intake manifold and throttle body. Combined with the freer-flowing Heavy Breather Elite Air Cleaner and High-Flow Exhaust System we selected to complement the Stage 4 Kit, we bumped up our H.O. Twin Cam 103 s output from 66 hp and 80 lb-ft of torque to 95 hp and 100 lb-ft of torque, as measured at the rear wheel on a DynoJet chassis dyno. That works out to a 44 percent increase in horsepower and a 25 percent increase in torque, that, along with the throaty rumble of the Screamin Eagle High-Flow Exhaust System with Nightstick Mufflers, put smiles on our faces the first time we grabbed a big handful of throttle. the Screamin Eagle parts take it to the limit of 50-state street-legal performance Camshafts» Camshafts influence the character of an engine s power curve by controlling the volume and timing of air entering the cylinders and the RPM range where the engine makes peak power and torque. Compared to the stock camshaft on the right, the larger lobes of the Stage 4 Kit s SE259 camshaft open the valves sooner, lift them higher, and close them later, allowing more air and fuel into the cylinders. Heads» The Stage 4 cylinder heads are machined with larger intake and exhaust ports to flow more air into the cylinders, and a smaller combustion chamber that matches the Screamin Eagle pistons to raise the compression ratio. 42 V O LU M E 26 HOG MAGAZINE 51 VOLUME 24

5 Pistons» The Stage 4 Kit s highcompression forged aluminum Screamin Eagle pistons raise the engine s compression ratio to 10.5:1, squeezing the air/fuel mixture harder to produce higher cylinder pressure and more power, while still running on standard 91-octane gasoline. Installing the kit involves quite a bit of know-how and many specialized tools, so you ll want to take your bike to the service experts at your favorite dealership to have the job done right. We brought our Street Glide to Harley-Davidson s Fleet Center near Los Angeles, where Master Technician Alan Barsi manages a fleet of motorcycles regularly used for magazine testing and Hollywood productions. If you ve seen Sons of Anarchy or read bike reviews in magazines like Cycle World or American Iron (and even HOG!), Alan is the guy who keeps those bikes in top condition, and he had our Street Glide torn down and back up and running in an afternoon. Manifold/Throttle Body» Combined with the Heavy Breather Elite Air Cleaner Kit, the Stage 4 Kit s 58mm throttle body (left) opens wide to gulp more fresh air into the engine. Watch a behind-the-scenes Project Bike video, hear the sound of the upgraded engine, and more at hog.com/projectbike or in the HOG tablet edition at hog.com/tablet. Pressure Plate» Screamin Eagle recommends changing the clutch pressure plate spring to a heavy-duty version when raising the engine s torque output by more than 10 percent. It s included in the Stage 4 Kit. Muffler» Louder doesn t always mean better, but the street-legal Screamin Eagle High-Flow Exhaust System with Nightstick Mufflers looks and performs as great as it sounds. Wide pipes and high-flow catalysts reduce backpressure and keep emissions legal in all 50 states even California. PROJECT LIST PART Screamin Eagle Street Performance Big Bore Stage 4 Kit Screamin Eagle High-Flow Exhaust System with Nightstick Mufflers Screamin Eagle Heavy Breather Elite Air Cleaner - Chrome PART NO. PRICE $1, $1, $ The prices appearing here are the manufacturer s suggested retail prices. Actual retail prices may vary. 44 V O LU M E 26

6 Ball Boys Since 2011, Harley-Davidson motorcycle riders have delivered the game ball prior to the first pitch at all Milwaukee Brewers home games at Miller Park, culminating in a crowd-pleasing lap around the warning track. H-D emarketing Specialist Dan Wilde made the special delivery aboard the HOG project bike at the August 5 game against the San Francisco Giants. To see the latest additions to the project bike, visit hog.com/projectbike. Photograph by Brad Chaney

7 PROJECT BIKE Project RUSHMORE Is a Wrap Big wheels, bold chrome, and lights bright enough to land a small plane at night are the recipe for the final round of modifications to HOG s Project RUSHMORE Street Glide Special project bike. By MATT KING Photography by BRAD CHANEY HOG s Project RUSHMORE project bike in the lobby of the Harley-Davidson Juneau Avenue Headquarters, Milwaukee. From the start, our goal has been to dial up the style and functionality of our Street Glide Special motorcycle with parts from the Harley-Davidson Genuine Motor Accessories catalog, and we ve hit all the highlights along the way: touring and comfort, engine and exhaust, audio, wheels, and lighting. We cap off the year-long project bike build in this issue with new Aggressor wheels, a chromed-out front end, and DaymakerTM Reflector LED lighting, along with a few additional chrome accessories that add a touch of class.

8 Functionally, the biggest step forward comes from the DaymakerTM Reflector LED Headlamp and fog lights. Compared to traditional halogen bulbs, LED headlamps provide superior lowand high-beam performance, with a wider pool of light in front of the motorcycle and more punch down the road. Solid-state LEDs are shock- and vibration-resistant, and fit existing housings for easy installation. Engine guard-mounted LED auxiliary fog lamps enhance the ability to see and be seen even further. For more information on the benefits and options available with H-D LED lighting, visit hog.com/projectbike to view the LED lighting video. Like any project bike, ours may never truly be finished Next up are Aggressor wheels, the newest in H-D s burgeoning lineup of custom wheels. With thousands of hours of real-world testing backing them, you can count on H-D wheels to deliver the highest standards of performance, durability, and style. The chrome Aggressor wheel set pairs a larger 18-inch rear rim (requiring a new tire) with a stock size 19-inch front for a solid, classy foundation. Matching polished brake rotors complement the wheels, and we capped it off with chromed fork lowers and windshield trim, and smoked turn signal lenses. Like any project bike, ours may never truly be finished, but we ve built a machine that stands out in a crowd, and, more importantly, we ve made it our own in terms of style, performance, and comfort. We ve proven this on several long-distance road trips throughout the year, including riding the length of Route 66, and from Milwaukee and back on the recent New England Trailblazer H.O.G. Touring Rally, (Pages 40-44). It has performed without a hitch, been a joy to ride, and has turned heads along the way. Above: A Daymaker Reflector LED Headlamp lights up the sky, cutting a longer and wider swath of visibility on the road, day or night. Below: Chromed lower fork sliders and caliper screen inserts complement the Aggressor wheels and matching Aggressor brake rotors with polished carriers. FRONT END PART PART NO. PRICE Lower Fork Sliders Chrome Upper Fork Slider Covers Cast Chrome Caliper Screen Inserts Chrome $ $ $59.90 WHEELS & ROTORS NEW Aggressor Wheel 19" Front, Chrome NEW Aggressor Wheel 18" Rear, Chrome NEW Aggressor Polished Brake Rotor Right NEW Aggressor Polished Brake Rotor Left $ $ $ $ LIGHTING & ELECTRICAL Daymaker Reflector LED Headlamp NEW Daymaker Reflector Fog LED Lamps Chrome NEW LED Fog Lamp Engine Guard Clamp Kit Chrome NEW LED Fog Lamp Wiring Harness NEW Auxiliary Switch Kit Bullet Turn Signal Lens Kit Front, Smoked $ $ $49.95 $24.95 $68.46 $ A A $ $25.95 $59.95 OTHER Chrome Windshield Trim Grooved Classic Timer Cover Chrome Oil Cooler Cover Kit Chrome See additional Juneau Avenue photos and project bike videos at hog.com/projectbike or in the HOG tablet edition. hog.com/tablet 48 V O LU M E 28