“bike-in-the-box”

The finished motorcycle. Upswept 2-into-1 D&D exhaust is stylishly sporty but hellaciously loud.

My February 2007 issue of Cycle-World has the conclusion of their two articles on a “bike-in-the-box” kit-bike.
It was a nice idea: a manifestation of every sport-biker’s dream; a sport-bike powered by a souped-up Harley V-twin.
Using the Harley (clone) motor required certain limits: e.g. the design of the frame (no massive spars), and not a single-shock rear-end.
Still the end-result is not that far off. Quite a few sport-bike accouterments remain; like light weight, and excellent brakes and tires. (And of course, the motor makes gobs of torque.)
The bike came as a kit to the CW garage, everything in a large crate.
That included a massive 110 cubic-inch Harley-clone motor by RevTech, an offering of CCI (Custom Chrome Inc.), supplier of the kit. 4-inch bore by 4&3/8th-inch stroke; 114.6 horsepower at 5,600 rpm.
I no longer have the issue (May 2006) that had article #1, the build, but I do remember they were amazed that everything was there — usually parts are lacking; parts instrumental to completion of the build (like a wiring-harness, for example).
They also commented the build would need a good mechanic; which the writer was. He was the one that put it all together.
The only problem was the chainguard/fender, which they finally used after replacement #3 centered over the tire; but the chainguard still didn’t center over the chain.
Once assembled, and registered (massive hairball), testing could be done, during which they ascertained two things: A) the Harley-bits activating the brakes were a poor match, B) the massive Harley foot controls liked to scrape the pavement, and C) despite mounting the motor in rubber (the Harley-system), it was a heavy vibrator — poorly matched to the lighter weight.

Sparks a-flyin’.

There is a photo of the bike leaned over in a turn and those foot-controls are throwing a shower of sparks.
The writer also commented his left-foot boot was shoved out so far by the Harley clutch-cover, the pavement would knock his boot clear off the peg.
CCI was bought-out by another investor that refused to allow CW to test. —It was their bike. —Plus CCI stopped selling kit-bikes; the “bike-in-the-box” was now an orphan.
So CW had to buy the bike, and register it, to test it.
Registration was a massive hairball; insanity compliments of the California DMV.
The bike was “specialty construction,” requiring a number of inspections by DMV drones. The writer was required to get DMV-certification of the brake- and taillights, and of course such a certifier was nonexistent.
Final certification required observation and approval by the California Highway Patrol, and the writer was sent around Robin-Hood’s barn trying to do this.
Months passed, but finally a CHP-inspector came out and glanced at the bike — loaded dead into the back of a pickup — and approved it (about five minutes).
So registered, it was tested. It would do 137 mph.