Double Head Development :: Motorcycles :: Mobster

Why I did started modifications?
Well, I always wanted to have a bike with high handlebar ;) Besides, Mobster had following defects:

no reseve (and I had to push this heavy bastard to the gas station twice)
a little mess in wiring harness
gear shifing rod made from rusting iron
open cooling system, because of which in traffic jams cooling fluid was boiling
veeery weak brakes

So, let's get to the work ;)

List of visible modifications:

High handlebar (ape hanger) Highway Hawk
Wiring inside of handlebar
Gears shifting rod made from inox steel
New rear turn signals
Saddlebag supports
Driver footpegs moved 4cm to the sides
New chrome headlight with visor
Leather grips with chrome ends
Steel brake line
Two-piston caliper from GS 500 (much better brakes)

List of invisible modifications:

Cooling system modified from open to closed (original parts from VZ 800)
Electric driven fuel cock (my own idea :) )
Reinforced gas lines (they look like rope)
Fixed wiring harness
Relays to minimize voltage drop
Open air filter
re-jetting using Factory Pro set (bike acquired much more power with moderate increase of fuel consumption)

Remarks:

Highway Hawk handlebars are relatively cheap, but have some disadvantages. One of the problems is that this handlebars do not keep cross-section profile on bents. The next problem is that the holes, that according to description should be for cables are in weird places and have small diameter (6mm). I think that someone made strange mistake writing that holes for cable holders are holes for cables. Material for handlebar is a little bit too soft.
Wiring in handlebar: to provide all the required signals, I needed multicore cable. I made 8mm holes in handlebar; for this diameter I was able to insert 5-core 1mm²cable - a little bit too small. I've decided to add relays and for handlebar wiring I used YTKSY 7x0,5mm² cable. Such cable is able to carry 4A safely, so I installed relays for:
- lights (1 pc, switching between HI/LO)
- turn signals (2 pcs)
- brake light (1 pc)
- horn (1 pc)
Whether there is a need to use relay for horn - it's moot problem, but as it's inductive element, so thin cable could cause high voltage loss and heat emission. Clutch switch, engine top switch and starte button were connected directly using 0,5mm² cable - it's enough.
In the begining, relays were under frame neck, but then I made small circuit with microrelays that fit inside headlamp.
If you plan to thread inox steel, buy robust die. Weak tools could loose tooths or even could break in half.
Cheap saddlebag support for Savage available in Louis shop does not guarantee trouble free installation. According to manual, in the front it should be installed over fender strut, in the back - below it. The problem is that strut is 20mm wide, but saddlebag support mounts are in one plane. Installation is possible, but not easy.
Electric driven fuel petcock - I had no original petcock, so I used two electric driven fuel valves and a switch. I used two way switch, but three way switch could also be used and in the middle position fuel would be cut off completely - simple anti-theft protection.