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2007 FLTR Zippers/Baker Build

5K views 24 replies 7 participants last post by  Rat tail 
#1 ·
My 96 c.i. motor was starting to build some carbon on the plugs so at 111,000 miles its time to rebuild, the trans had been rebuilt at 80k but the main-shaft bearing was going also. With new bikes at almost 30k this is a bargain.
 

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#2 ·
So here is the new parts list, retail pricing

Zippers Muscle 107" Kit for 2007-Up Big Twin Cable-Throttle Models, Silver +$3,449.00
Baker GrudgeBox $3,395.00
Baker Sleeper trap door $250.00
Baker Compensator $499.00
Baker Primary Chain Tension Adjuster $249.00
Screamin Eagle Variable Pressure Clutch $280.96
Screamin Eagle Performance Clutch Friction Disc Kit $159.43
Screamin Eagle Twin Cam Performance Race Clutch Hub Kit $248.06
Chrome '95-'08 Touring D&D Fat Cat, Straight-Cut, Wrapped Big Bore Baffle +$999.00
S&S Balanced Wheels 4 3/8 stroke with Full-Width Rod Tops for 2007-Up 'A' Twin Cam® Engines +$1,517.95
Zippers Blueprinted Billet Cam Plate for '99-'06 TC Engines +$419.95
Feuling® OE+ 2007-up oil pump assembly +$239.95
Jagg oil cooler $329.95

I'm not sure on the throttle body yet and there are a lot of misc. parts like rotors, oil temp gauge, etc.

Right now my retail parts are at $13,589.79 without any labor
 
#13 ·
4 inch jugs from the MoCo, have the spigot holes cut, the case has to come out of the scooter anyway. Pistons from whatever floats your boat, and run the heads through zippers or some other shop. Eazy start S&S gear drive cams that fit your needs. S&S cam plate and three stage oil pump. New jug studs. Skip the adjustable push rods unless you plan to run roller rockers. Just use SE tapered rods. 110 inches for less cash.
 
#6 ·
So far the only new part I have is this Jagg wide-line oil cooler that will mount on the left side frame upright. It's next to my old HD chin mounts cooler for comparison. I never liked the oil cooler in front of the voltage regulator so one of them had to move.
 

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#7 · (Edited)
I also took this opportunity to clean up my fork lowers, just with sandpaper. I started at 50 grit and went to 800 and used the files to get out any casting seams. I like the brushed look finish better than polished and this rebuild is just about clean dependable power because I like to ride long distance, so paint and chrome won't come into play here.

More to come soon, I have a delivery coming and my motor might be done Friday.
 

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#9 ·
Some misc. parts are tricking in so I'll be putting it back together this coming week. I also got to see my motor on Friday and it looks awesome and that should be finished this week. I originally was thinking Zipper's would just do the machine work and bottom end but I'm spending too much money to make any mistakes and these guys/gals at Zipper's are just so versed on these motors that it makes your head spin, plus I get a year warranty on their work if they finish the work and fire the motor. It's good peace of mind for me.
 

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#10 ·
Things have been moving slow but the bike has 3 new brake rotors, new stoplight switches front and rear, new DOT 4, a oil temperature gauge, and a new windshield. My motor is close to being done, just waiting on a Horsepower Inc. throttle body and everything at Baker is on back order and expected at the end of June.
 

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#14 ·
I just used a stock HD oil temperature gauge so it would match my existing cluster, it will be good enough to give me a heads up that things are getting too hot. No plans for shocks or any other upgrades, we have a trip to Sturgis and the Tail of the Dragon planned so I'm about done spending.
 
#15 ·
I went into Zippers with a list of parts but I told them to correct any items that they didn't like, so they pretty much tossed my whole list except for a SE oil pump, they said once you fix the problems in the camplate the SE pump had more that adequate presser for my build and it saved me some cash.

I am so happy I went to Zipper's, their knowledge and attention to detail far exceeded my expectation, so I fully trust and value any advice they offer.

This is a example, so they will do your build anyway you like and some might want SE parts so this is a example of a SE camplate bore for the pressure relief valve under magnification and that valve needs to seat at the end of the bore. Zipper's inspects every part they intend to use and this is what they found.
 

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#17 ·
Here is what I ended up getting after the guys at Zipper's tweaked my parts list.

Zippers Muscle 107" Kit for 2007-Up Big Twin Cable-Throttle Models, Silver +$3,449.00
Baker GrudgeBox $3,395.00
Baker Sleeper trap door $250.00
Baker Compensator $499.00
Baker Primary Chain Tension Adjuster $249.00
Zipper's Variable Pressure Clutch $306.95
Horsepower Inc. 58mm/1.730 Throttle Body $799.95
S&S TC/00+XL Lifters $146.95
Chrome '95-'08 Touring D&D Fat Cat, Straight-Cut, Wrapped Big Bore Baffle +$999.00
S&S Balanced Wheels 4 3/8 stroke with Full-Width Rod Tops for 2007-Up 'A' Twin Cam® Engines +$1,517.95
Zippers Blueprinted Billet Cam Plate for '99-'06 TC Engines +$419.95
SE 2007-up oil pump assembly +$149.95
Jagg oil cooler $329.95
A lot of new gaskets, sprockets, chains, brake rotors, windshield, etc.

Total build cost to date, labor included $15,446.74
 
#18 ·
Baker won't ship for a month so the old trans is going back in for now, my goal is get the motor fired by Wednesday. I just got the intake finished up, a few bearings in, and the old trans cleaned. The main bearing was trashed but it's new for now and hopefully it will get me past the break-in.
 

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#19 ·
The bike is up and running, Zippers primed the oil system and heat cycled the motor, the old trans and compensator will have to do until baker ships my order. The normal oil temp is about 210 degrees with 43 pound of oil pressure, torque and HP are about 120 and the bike is a lot of fun to ride. I would highly recommend Zippers, their expertise, quality, and service is exceeded by none.
 

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#20 ·
I've been riding it for 10 days and 1,850 miles, oil temps about 195 on a 90+ degree day but it will climb to 230 degrees after about 10 minutes in stop and go, oil pressure is 43-45 psi at highway speed, my best mpg is 47.5 on a tank riding back roads in PA., I've only cracked the throttle a few times during breaking but the front tire was 2 inches off the ground in third gear which was awesome.

I've just switched from conventional oil to Redline synthetic and NGK iridium plugs, immediately i noticed it starts easier and runs smoother and cooler, plus the Thundermax ECM is still learning and improving the ride.

I'm very happy with this build and will never be able to go back to a stock motor.
 

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#21 ·
I had to switch back to stock HD spark plugs, the NGK iridium plugs are a little hotter so it's like advancing the timing too much, it started to ping bad after a hot ride in some stop and go traffic, I had no idea this could happen so I thought I'd share so it doesn't happen to you.

Other than that it's running perfectly
 
#22 ·
Everything is good, the bike has 4,100 miles on the new motor. We went out for a 320 mile ride Saturday, it got hot mid-day and my wife on the back, so it started pinging and clicking a little when I'd roll on the throttle easy, between 2,200 to 3,000 rpm but no problem in the morning when it's cool. Sunday I changed the oil in all 3 holes and took off the primary cover, the new baker attitude adjuster looked great but the primary chain had a extra 1/2 inch of slack in it from the chain seating into the new adjuster shoe, I tightened the chain to the tightest spec. and my timing issue was fixed, no more ping or chatter when I roll on the throttle.
 
#23 ·
I just want to give Zippers Performance a review, After a little over a year I have racked up 32,000 miles on my new motor. When I started this build with Zippers I was told due to the nature of high lift cams that tappets would be a wear item and most likely would last between 20k to 25k and I did need a set at 22k. But otherwise the motor has not had a single mechanical failure and with 124 hp and 122 tq out of a twincam, well I am more than impressed and it was money well spent.
 
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