FREE Bike Build Parts Checklist...

wide tire show bike

This parts checklist is for those of you who want to get more organized when building your bike.

It's a free motorcycle bike build checklist and there is no obligation to buy anything.

But we would appreciate the support because this site is for fun and just a break even project. 

Parts Check List For Planning A Custom Motorcycle Build.

Note: This is not meant to be fully comprehensive list.

It is only to help you consider the necessary parts required for your specific build and to help you budget for each part and mark the order in which you wish to purchase each item.

Many of us cannot buy the entire array of parts at one time so a checklist like this should be of some assistance in the long run.

Engine: (choose type you wish to use and note engine size).

Second Hand

New Complete - Assembled

New Complete - Unassembled

New Long Block - Assembled

New Long Block - Unassembled

OEM - Evolution

OEM Twin Cam 'A'

OEM Twin Cam 'B'

Aftermarket Evolution-Style

Other 

Parts Required to Complete Engine:

Alternator Stator

Alternator Rotor

Regulator

Regulator fasteners

Oil Filter Mount

Crankcase Vent 1)

Crankcase Vent 2)

Head Breather & Mount

Alternator Cover-for 3 or 4in open belt

Carb-1)…..single carb setup

Manifold & fasteners for above

Carb - 2)…..dual carb setup

Manifold & fasteners for above

Aircleaner-1)

Aircleaner Mounts(Carb 1)

Aircleaner-2)

Aircleaner Mounts(Carb 2)

Aircleaner covers

Breather Kit

Throttle Cable - see below

Choke Cable & Choke Knob….custom knobs available

Cam Cover

Cam Cover fasteners

Ignition Cover & hardware

Rocker Box Covers-(2) & Hardware

Pushrod Covers

Oil Cooler & Mounts

Ignition Lobe

Ignition (Single or dual fire - Points or Electronic)

Coil (Single or dual fire - Points or Electronic - Single or Dual Plugs - Check on resistance!)

Coil Mount(coil & motor mount)

Plug Wires

Wire Separators

Balancer 

Engine sprocket kit

Oil Pump

Engine Gaskets-Top/Bottom/Complete (Buy as a complete kit if possible-You will save money compared to buying separately)

Engine Bolts / Nuts / Washers

Exhaust System

Exhaust System Brackets / Gaskets / Flanges / Spring Retainers

Primary Transmission:

Outer Primary & Finish

Inspection Cover

Electric or kick start

Derby Cover

Inner Primary & Finish

Inner Primary 'O' ring-use two if offset primary spacer is needed

Inner Primary offset spacer

Primary Gaskets

Primary Case Hardware

Clutch & Chain or Belt Drive

Clutch

Primary Chain

Chain tensioner

Belt Drive

Starter Unit 

Transmission:

4 / 5 / 6 speed or 5 speed in 4 speed box

5 speed with reverse gear

Right side drive transmission

Electric start

Kicker kit

Additional Side Cover & Finish

Additional Top Cover & Finish

Hydraulic clutch brake hose

Transmission outrigger support/bearing

Transmission Plate

Transmission output sprocket / pulley(Teeth)

Offset Transmission sprocket

Offset kit for wide tire

Frame:

Left or right side drive

Chassis

Rake Desired

Stretch Desired

Steering Neck height - additional or stock height in inches

Determine additional height, if required, for higher than stock motor

Brackets- pulley cover / brake brackets / other

Wide Frame

Wide swingarm

Swingarm if soft tail configuration is desired

Single side swingarm

Swingarm bearings

Distance Axle

Distance Axle Nuts

Stop ring

Sprocket Spacers

Rear axle spacers

Rock Guard/fasteners

Additional Parts to complete Chassis:

Motor Mounts(Top/Front/Transmission)

Rear Belt Guard Mounting Lugs

Side Mount License Plate Mounting Lugs

Gas Tank Mounts

Engine case protector

Brake Caliper Torque Arm Mounting Lug

Headstock bearings

Headstock bearing cups

Triple tree dust shields

Rear Shocks

Rear Shock Mounting bolts / nuts / washers / spacers

Air Dam & Fasteners

Seat - Single or dual, custom made, off the shelf? 

Seat fasteners if not included with saddle

Fuel System Tanks:

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Fuel - type, capacity, length

Petcock - 1)

Petcock - 2)

Fuel Pipe

Tank Cap - 1 or 2

Tank Breather

Tank Breather Pipe

Fuel crossover tube

Tank Mounting hardware

Gas tank grommets

Dash if desired

Oil Lubrication System:

Oil Tank make and finish

Oil tank fitting

Oil hose

Oil hose separators

Carb Cables - Push / Pull, Braided or Plastic, length

Clutch Cable - Braided / Black / Length

Clutch Hydraulic Hose - Braided / Black / Length

Front Brake Hydraulic Hose - Braided / Kevlar / Black / Length / Splitter 

Possibly Required - Type of fittings at caliper and control ends

Rear Brake Hydraulic Hose - Braided / Kevlar / Black / Length / Stop Light Switch 

Possibly Required - Type of fittings at caliper and control ends

Offset Components: For use with chain or belt final drive.

Primary Spacer-width & longer bolts

Extended engine sprocket extension

Transmission Mounting Plate

Offset Transmission Sprocket

Wheel Spacer

Front End:

Fork (make/length/dual or single disc/wide, mid, wide glide

Increased rake triple trees are possible…also adjustable rake triple trees up to 13deg

Wheel- size/wide or narrow glide

Wheel bearings - Specify pre 99 or 2000up wheels

Front Tire-Make and nominal size

Front Tire-Overall width

Front Tire-Overall diameter

Inner Tube (check valve angle with angle of hole in rim)

front axle / nuts

Discs (Size)

Disc Bolts

Brake Calipers

Brake Caliper Brackets

Brake Hose

Speedometer 

Speedometer Drive 

Speedo cover

Speedo Mounting

Speedo cover

Tachometer & Drive

Tachometer Mounting

Fender & Mounting nuts / bolts

Fender Brackets on forks (Sometimes integral with fork and sometimes separate)

Headlight

Headlight Mount and bolt / nut

Handlebars (internal wiring?)

Handlebar Mounts/Risers including bolts

Handlebar Dampers

Brake Master Cylinder (5/8in for single disc/3/4in bore for dual disc)

Clutch Levers

Brake hose - type and length

Clutch Levers - cable or hose

Light Switches

Handlebar Mirrors

Handlebar Grips

Forward Controls (5/8in or 3/4in bore & Extended)

Forward Control Shifter Rod

Rear brake hose - type and length

Stop light switch (can be specified when selecting hydraulic hose)

Front Indicator Light  /mounting

Disc Bolts(5) 5/16in Counter bored

Rear End - Specify pre 99 or 2000up wheels:

Wheel- size

Wheel bearings

Axle, nuts and washers

Rear Tire - Make and nominal size

Inner Tube (check valve angle with angle of hole in rim)

Rear Tire -Overall width(relevant to frame / swingarm / offset)

Rear Tire - Overall diameter

Fender (fenders with internal struts can save on buying struts and offer a cleaner appearance) 

Fender Struts & hardware

Sissy Bar if desired

Brake Disc

Brake Caliper

Brake Caliper Bracket (stock fitting or using torque arm fixed to swingarm)

Rear Light

Rear Indicator Light / mounting

License plate mount

Side mount license plate set up

Rear Belt or Chain(number of teeth)Ask frame manufacturer what chain/belt lengths & sprocket/pulley combinations are possible

Rear Belt Pulley or Chain Sprocket(No of teeth) Belt pulley-1-1/8in or 1-1/2in wide?

Disc/pulley/brake kit

Disc/sprocket/brake kit

Disc Bolts(5) 3/8in countersunk

Pulley Bolts(5)

Passenger Pegs/Mounts

Number of teeth on rear sprocket/pulley should be determined in relation to engine power characteristics and rear wheel size

Pulley Guard or Chain guard - Upper and lower

Other:

Sidestand

Sidestand lowering spacer

Wiring harness

Other Electrical Items

Battery

Custom Switch relay

Oil Pressure Switch

Miscellaneous - Nuts/Bolts/Anything Not Already Included

Cable ties

Cable separators

Horn & Mount

Ignition Switch

Frame preparation

Custom Paint Job and molding

Labor cost of subcontracted out work

Lubricants:

Brake/hydraulic clutch line fluid - Correct DOT number

Transmission Oil

Primary Transmission Oil

Engine Oil

Bearing Grease

Thread lock

Fork Oil - correct SAE number


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What Other Visitors Have Said

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Affiliate Bike Builder Sites 
It would be nice to have affiliate sites for the broader scale of bike builders i.e. replica part sites for the old Jap bike re-builders. Life is not just …

Part list is right on Not rated yet
Downloaded your parts list, something I've been looking for, for a while now. Its seems pretty long, but after going through it I think its right on. …

Additional parts that can be mentioned Not rated yet
Personally the list is very organized, and as required but just want to make 1 suggestion that along with the swingarm listed there should be also a list …

More detail for the nitty gritty things to take in to account Not rated yet
What I really miss, is the details of what parts I have to take in to consideration when I want to change the original motorcycle setup. I think that most …

sporty build coming Not rated yet
Looks good so far have sporty build coming up in Apr2010 we will use check list & reply after job end.

Very Useful! Not rated yet
This parts checklist is very useful for preparation and budgeting.

Type Of Frame Not rated yet
Maybe you can add to checklist a type of frame - hardtail, softail etc.

The checklist is fairly complete Not rated yet
I think the checklist is fairly complete.

Opening my own chopper shop and this helps Not rated yet
I think its great I love it. I am trying to open my own chopper shop so this helps out a lot. The only thing I didn't see was anything about a seat pan. …

Nice Job On The Parts List Not rated yet
That parts list that they sent me was awesome, there's a lot of stuff on there that I never even considered for building a bike. Thanks it makes things …

Include parts of major assemblies Not rated yet
I would suggest putting the parts of major assemblies in a form like below; Electrical; Generator (alternator) Regulator Ballast (resistor) …

Simpler Parts List? Not rated yet
I don't know if this will sound stupid or not, but what about a simpler list? I mean, I read this one and it seems to be from scratch...what about for …

LOOKS GOOD ALREADY... Not rated yet
I don't have any suggestions at this point-- maybe something to skew it away from just harley davidson based choppers? Mike

Click here to write your own.

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