We rode about 250 miles during the Maine rally and as expected, a few issues developed.
1. cant seem to keep the oxygen sensor tight in the front exhaust pipe. Lets me know when it’s loose, runs poorly. Any tips on how to keep it tight?
2. oil cooler I bought, new in box, was actually at least 8 years old leaked badly.and the fan never activated. Tech at UltraCool suggested I take it off and throw it in the garbage. The seller was nice enough to refund my money. Just finished installing a brand new (2025) cooler. Hoping to test it soon.
3 steering damper loosened up and slipped down, forgot thread locker.
Will keep up testing and hope to have it completely sorted before paint.
Dave, on item #1, the oxygen sensor not staying tight in other leaders pipe:
Safety wire it into a locked position. Drill a 1/16" hole through one of the 6 hex corners, then use .032 safety wire, through that drilled hole, and lock that O2 sensor down.
If you are not familiar with how to do Safety Wiring, lots of info online, and videos.
Two Million Mile Rider
Exploring the World in Comfort
Is that a stock front pipe or aftermarket. There is no reason to have to safety wire it. If it's aftermarket the bung is probably not machine right.
Aftermarket, it’s a Vance and Hines system front to back. I did write to them, waiting to here back.
Vance and Hines said they’ve never had a problem with O2 sensor loosening up. Will try the recommended anti- seize and retorquing.
-Taking the pattern and marine vinyl to be sewn today for new tonneau
-Windshields added recently
-Fabricating mount for rear view mirror this week
In another week I’ll be out of planned work and have to decide when to stop riding and
start final body work and paint.
Dave, it's looking really good !
Is it really necessary to have the rear view mirror mounted onto the sidecar body ?
In a poll taken recently, only 3.14159% of all sidecar Monkeys said they had a need or want for a rear view mirror on the sidecar.
And, most tonneau cover makers really like to have the vehicle present, in their shop, so they can make the new tonneau cover to precisely fit the vehicle, in this case the sidecar, rather than just go off a pattern.
Painting...color ???? Are you going to repaint the bike, so that it matches the sidecar ? 
Two Million Mile Rider
Exploring the World in Comfort
Definitely looking great!
A stand out feature that caught my eye is how the sidecar windshield matches the bike's windshield. Trim layout, size and curvature. Really dig details like this.
How are you enjoying the ride?
Hold my keyboard and watch this! 🙃
Forgot to mention the O2 sensor. You may already know this, but just in case:
Some exhaust systems come with copper washers the size of the O2 sensor bung. They are only used if a blocking plug is used to replace the O2 sensor. If used in combination with the O2 sensor (which should have a crush washer already), the O2 sensor usually works it's way loose.
Slight haze of high temp anti-sieze and proper torque is all that should be needed. If the O2 sensor comes loose under these conditions, suspect the bung thread cut depth, and/or damage to the O2 sensor threads. A thread gauge can be used to check the threads in both cases. The thread gauge should make complete contact with the threads.
Another possible issue is high vibration from a lean running cylinder (harshness causes sharp, rapid pulsing). I don't have any personal experience with HD, so would defer to someone with good first hand experience to troubleshoot for resolution in this regard.
Hth,
Hold my keyboard and watch this! 🙃
I am enjoying the rig so much that it’s hard to think about shutting it down for paint especially given the late start for my riding season. Thanks for your feedback and comments!
I guess my monkey is of the minority in your poll.
Im trying the tonneau on my own with only the sewing being subbed out. The turnbuckle style connectors are not on the tub and will be added to the tub and cover one at a time to make sure the placement is exact.
Plan B is to take it to somebody who knows what they’re doing, but only if plan A does not work out.
My plan A and B method of the build has worked so far and with everyone’s help the Plan A has prevailed.
im using marine grade canvas for the tonneau and there is no stretch to it. Wondering if that will require a plan B, I’ll keep you posted.
Forgot…….. the tub is currently in grey primmer and will be painted to match the bike. It will be satin black with some old school pinstriping.
i have to change the finish on a few items so everything matches. Those details and maybe even the paint may be a winter project.
According to my monkey, my next project is to get the barns stained.
Glad to read you are having a lot of fun with it. Has been a lot of fun to follow along on the project. Sure is turning out great! 👍
Hold my keyboard and watch this! 🙃
