DIY Network

Introduction and Evaluation, Pt. 1: Mechanical From "Classic Rides" episode DCLR-101

In the first episode of nine, this rundown '65 "Electra Glide" will be evaluated before the restoration project begins.

The 1965 Harley-Davidson Electra Glide that host Kevin Tetz (a restoration and bodywork specialist) and Harley expert William "Dunk" Dunkelberger restore in our nine-episode classic ride project has seen a lot of hard miles and plenty of fun living. It needs a lot of work and in nine weeks you'll see this classic American icon restored to its former glory!

Our Harley-Davidson Electra Glide motorcycle is a great example of an important time in motorcycle evolution because it was the first American motorcycle with an electric start -- hence the name Electra Glide. In fact, 1965 was the only panhead (motorcycles manufactured by Harley-Davidson from 1947 to 1966 -- also officially known as the FL model, in which the motor has an overhead valve configuration as opposed to a side-valve configuration) to have both the electric start and traditional kick start.

Did You Know? -- The panhead earned its name from the appearance of the valve covers, which are deep D-shaped pans bolted to the top of the cylinders.

Our project Harley is road-worn and in need of some cosmetic -- as well as mechanical -- work. Throughout this nine-episode restoration project a wide variety of tasks will be tackled, including mechanical repair, painting and detailing and accessory enhancements. But the first thing our host and his cohort, Dunk, need to do is a good evaluation.

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	Figure A
	Figure B

Evaluating the Electra Glide

Before the restoration can begin, our host and expert need to go through a checklist of things to evaluate to determine whether the bike is ready to run and drive:

• Inspect the fluids.

  Warning: You never want to start an internal combustion engine without determining whether the fluids are contaminated or not. If they are the internal components of the engine could be damaged.

• Check the fuel system. The first thing to inspect here is the gas cap (figure A). Check for signs of rust, moisture damage or any kind of water beads. Moisture in the fuel tank will definitely contaminate the inside of the motor and rust the gas tank.

  Tip: Remember that gasoline doesn't last long and if you're going to have your bike in storage for any amount of time, add a fuel stabilizer to the gas tank.

• Next up is the "sniff test," which consists of checking the smell of the gas. A varnish smell or anything that just doesn't smell right (a thicker smell, for example) is a good indicator that the gasoline has gone bad.

  If the gas is bad be sure to flush it and replace with fresh gas before starting the engine. Moisture or signs of debris in the gas also indicate contaminated gas tank that should be replaced.

• After inspecting the gas and gas tank, it's time to check the main gas line, which comes from the petcock (a regulator valve or faucet that controls fluid flow -- figure B) and goes over to the inline filter and then on to the carburetor. A cross-over -- or by-pass -- tube goes from one side of the tank to the other.

  Note: The petcock has an "on" and "off" switch, and if your bike is in storage for any length of time it should be on off.

  For this project the petcock will be replaced.

  Be sure to pry and test these lines to make sure the rubber is still supple and that there are no signs of dry-rot or cracking. And if any of the lines are touching be sure to separate them because that could cause some abrasion down the road.

• The carburetor inspection is next, and to be able to do this the air-cleaner assembly (figure C) must come off. Once the assembly is off inspect the cables, lines, bolts and clamps to make sure they're sturdy. If any are frayed or stressed, they'll need to be replaced.

  Note: For this particular project, the carburetor (figure D) was a later model for this motorcycle, so our host and expert decided to add replacing it with a new one with a high-performance upgrade on the restoration plan (more details for the plan in segment three).

• Check the oil for contamination. To do this remove the cap, dip out some oil with the dipstick and smear it around and inspect. Test for a burnt smell. Note that the oil system will be thoroughly flushed during the restoration and will upgrade to a modern drain plug with a magnet on it, which will trap any metal particles that are floating around in the oil system.

Figure C

Figure D

Figure E

Also during the restoration project a homemade oil cooler will be made out of the engine guard (figure E). We'll plumb an oil line from one end and it will circulate another half-quart capacity of oil all the way through, making a nice air-cooled oil cooler, which will help the bike run cooler.

Tip: Be sure to place cardboard under the bike to see if there are any oil leaks. This will reveal where the leaks are coming out as well, which means possible o-rings or gaskets will need to be replaced.

In the next segment the evaluation continues with the driveline, brakes, tires, chains, frame and general safety.

RESOURCES :

Harley-Davidson USA Information
Harley-Davidson USA
3700 W. Juneau Ave.
Milwaukee, WI 53208
Customer Service: 414-343-4056
Website: www.harley-davidson.com

Eazyrizer Big Blue Motorcycle Lift (Driven Gear)
Driven Gear Inc.
Website: www.drivengear.com

Knoxville Harley-Davidson Information
Knoxville Harley-Davidson/Buell
Website: www.HarleyofKnoxville.com

RaceDeck Modular Flooring (SnapLock Industries)
SnapLock Industries
Website: www.racedeck.com

Motorcycle Hall of Fame Museum Information
Motorcycle Hall of Fame / American Motorcyclist Association
13515 Yarmouth Dr.
Pickerington, Ohio 43147
Phone: 614-856-2222
Fax: 614-856-2221
E-mail: info@motorcyclemuseum.org
Website: www.ama-cycle.org/museum/

Ultimate Harley-Davidson
0789499746
Hugo Wilson
(October, 2003)
To order this title from Amazon, click here.
Dorling Kindersley / DK Publishing

Hugo Wilson's Hot Bikes
0751336947
Hugo Wilson
To order this title from Amazon, click here.
Penguin Books

The Harley-Davidson Century
0760311552
Darwin Holmstrom
(September, 2002)
To order this title from Amazon, click here.
Motorbooks International

GUESTS :

William "Dunk" Dunkelberger
Restoration Coordinator / Mechanic
Harrly Hoggs & Piggletts
1409 Piney Rd.
Maryville, TN 37803
Phone: 865-681-7699
E-mail: hoggsandpiggletts@yahoo.com