FreeSpirits, XR1200 Boss 88 06 November 15


FreeSpirits are a custom bike parts company based in Italy who specialize in Harley Davidson, Buell and Triumph parts and accessories. The also build bikes to showcase their parts and kits and here is their Harley Davidson XR1200 Boss 88

Forks
The unusual forks, risen from an old dream at FreeSpirits, where they combine the XR fork and Bitubo shock. The original fork is quite poor quality, in particular the first version, where there isn’t any adjustment, but due to the new shock absorber made by Bitubo, the forks now have a large range of spring preload, rebound and compression. The original fork is now completely empty (only oil to assure a smooth action of the tube on fork sleeve) the entire weight of the bike is supported by the lower trees, due to two tension rods that connect to the top trees (where the shock is attached).

Open primary
This primary was build originally to race with their Buell and as a result of the experience they also made it for the XR1200. To mount it, they completely opened the crankcase with the purpose of sealing the left case (closing the bottom hole “primary-gearbox” plus the hole that holds the two shaft shifter forks), and make a hole to drain oil from gear box. All the original bearings were replaced with sealed ones. It was also necessary to replace the original shifter drum bushing with a sealed ball-bearing, an while doing this they also replaced the right bushing, which will make the gear shift easier and smoother. With this modification, not only the inertial mass is reduced drastically but a good quality oil can be used in the gearbox without it getting ruined by the dust of the friction plates. Another modification done while crankcases were open was to balance the flywheel and mount a real big bore kit, now the engine is 1470cc. (88”).

Intake
Another simple by high tech solution it’s the high flow intake manifold, which is the first true performance air filter specifically designed for the XR1200 made with a huge 65mm elbow, produced by a unique patented process that allows the use of thin walled lightweight (only 305gr) construction. Back to back dyno tests have shown a 4.6CV (4.54bhp) increase over the stock filter arrangement (tested using same bike, same dyno, same day and same operator). This unit, which uses generation 3 Dobeck TFI technology, has several advantages over previous models. With this fuel injection unit mixture adjustment is by means of 3 push buttons on the top face of the controller. The air filter kit includes a well proven Sprint filter (water repellent) ‘Cone’ air filter, black finished tubular elbow manifold, Crankcase breather pipes, active intake valve emulator and required fittings. In addition, the new filter is water repellent so the classic "sock" isn't needed to protect it in case of rain.

Suspension
Although the XR1200 may be “sporty” by Harley Davidson standards, it is still a long way from being and handling like a modern sports bike. When the XR1200 race bikes were developed in Europe, they came up with the idea of using solid spacer blocks to raise the rear ride height by around 2" in order to quicken the steering, improve the handling and improve ride height. They took this same idea and, using their own test bike, have developed and fine tuned the riser blocks so that they are lighter, stronger and better looking than the original race parts. The original riser blocks used in the Spanish and Italian race series weighed 0.75kg each, theirs now weigh just 0.15kg each. These are manufactured from aerospace grade aluminium and anodized in black. Passenger footrests and associated hangers need to be removed in order to fit these blocks, as they use the same mounting positions on the frame as the original passenger footrest brackets. If using the stock or aftermarket exhaust pipes that attach to the passenger footrest then a new exhaust mount will need to be fabricated. These blocks are designed for race use and have not been tested or warranted for use on public highways. They significantly quicken the steering and alter the handling so care must be taken when first riding the bike with these parts fitted.

Triple Trees
This kit for Harley Davidson XR1200, offers replacement top and bottom triple clamps in lightweight CNC machined billet aluminium. The fork offset is 0 degrees, 1.5 more than stock and the same as the Italian XR1200 Trophy race version, therefore handling will stable (this is to partially compensate the raised tail with suspension risers fitted). The triple bolt bottom yoke is much lighter, stiffer and stronger than the stock item and includes a headlight bracket

Footrests
Multi adjustable billet aluminium CNC machined rearset footrests specifically to fit the Harley Davidson XR1200. Manufactured and anodised in black, these rearsets weigh just 1.56kg complete with all linkages, fluid reservoir etc (original footrests weight 2.8kg). These feature adjustable footrest position via an eccentric footpeg mount, which allows adjustment from the stock position to 2" up and back. Gear linkage gives more precise shifting. Includes new rear brake fluid reservoir and utilises stock rear master cylinder. No more scraping footrests around corners with these fitted.

Transmission
This light weight pulley replaces the stock one, made of aluminium billet the drive pulley features a changeable, surface hardened, special steel galvanised inner part which is totally stainless and has a reduced weight at 680gr. This 27 teeth pulley can be used to increase torque. Using the original belt. Part for Harley Davidson XL Sportster 2004-2013 and XR1200. The stock Harley Davidson belt tensioner is designed to keep the belt under constant tension, except it doesn’t. When the suspension is completely unloaded, such as when pulling stoppies or even braking hard, the tension is increased to an alarming degree, which can actually damage belts, wheel bearings and pulley bearings. This spring loaded item is designed to maintain a tension of 10.5kg (depending on model) regardless of swingarm position and will help lengthen belt and bearing life.

Brakes
The rear has specifications the same as the front set, this kit comes with banjo fittings to accept the original caliper or the 2 & 4 pot Brembo caliper, plus new hydraulic brake light switch. Part for Harley Davidson XR1200. Larger 320mm floating front discs give increased feel, better stopping power, and reduced brake wear compared to the stock 290mm items. This kit includes two anodised black billet caliper adapters, to reposition the original brake calipers, and two of the latest generation 320mm front brake discs. The braking surface is made of special high quality carbon steel, heat treated to the full thickness and is formed with laser cutting. The hub is CNC machined and is of a floating design.
205701: Complete kit with 2 piston Brembo caliper, mounting bracket and spacer (Bracket available anodised black or silver).It is recommended to replace original rear brake pipe with the kit 205703.

Accessories

  • Competition style headlight mask/number board with solid supports, EU approved projector style lights, aluminum alloy 'number plate' board. The wiring is designed to fit the original wiring loom.
  • Homologated (E Marked) LED rear/brake light. Includes brackets for turn signals and replaces stock plastics. Compatible with original tail and Fiberglass solo seat.
  • While top shock absorber was created to purely aesthetic, the bottom paddocks stand bobbins with new galvanized steel mounting hardware not only add more secure rear support but also acts as a protection.
  • Swingarm protectors easily fitted in seconds.They will save you from expensive damage in the event of a spill.
  • The dashboard plate for a Harley Davidson XR1200 utilises the original speedometer, tachometer and original lights wiring, with new billet aluminium surround/bracket incorporating the original warning lights. This model replaces the original bracket for use with original handlebar risers.

Bodywork

  • Ideal for those who want a solo seat look but want to keep the original seat. Installs using the original screws. The seat is not included. Supplied in unpainted fibreglass ready to finish.
  • Exact copy of the original tank cover, manufactured from extremely light fibreglass ready to finish. Uses stock fittings. Bolt-in kit.
  • Harley Davidson XR1200 fiberglass belly pan shaped to accommodate the side stand. Unpainted fibreglass ready to paint.

For more info: Click here

 

Alan Goodsell , 06 November 15