DIY Network

Evaluation, Pt. 2: Driveline and Safety From "Classic Rides" episode DCLR-101

	Figure A
	Figure B

Host Kevin Tetz explains that our project 1965 Harley-Davidson Electra Glide has been in storage for some time and there appears to be a lot of exterior parts that need to be replaced, but before the restoration can begin the evaluation process must be completed. In the first segment our host inspected the fluids and carburetor, and in this segment he'll check the tires, chains, clutch, brakes, frame and general safety.

Completing the Evaluation

• The rear brake is hydraulic, so the master cylinder (figure A) needs to be checked for signs of moisture and corrosion. The fluid level is good and there are no signs of moisture, so it's good to go.

• Next you'll want to make sure the feel of the pedal is firm, and you don't want it to go all the way down because that's an indication of air in the line. No our project bike the pedal is great.

• The front brake is mechanical, and it also feels good and solid, but it doesn't return and the cable is distressed (figure B). This will have to be replaced, but it will get our host stopped during the test drive.

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	Figure C
	Figure D

• Check the drive chain next. Signs for wear on a drive chain are lateral or side-to-side movement. This one feels tight, but there are some parts that are worn out. For example, the teeth of the sprocket are pointed and off to one side (figure C). They're pointing in one direction, and the sprocket is actually loose on the hub.

• The clutch is the next part to be inspected, and it feels fine. It has good lever action and good bounce-back action. Our host starts the engine to see how long it takes to engage, and our project bike has approximately 3/4" of travel, which is just about right, but the throttle sticks and hangs up. It will have to be fixed during the restoration.

• Treads, sidewalls and signs of dry rot need to be inspected where the tires are concerned. For our project bike the current tire (figure D) is the wrong style and will have to be replaced during the restoration process even though the tread and sidewalls look good and there's no dry rot.
  Note: Dunlop has been making tires for these particular Harley-Davidsons since the 1980s, and they've go the correct style bias-ply whitewall for the bike as well, which will look great!

• It's extremely important to evaluate the bike for general safety, such as the condition of the frame and loose items that could fall off during a ride -- and our project bike has plenty of them, which will be replaced during the restoration.

Figure E

• Also check the headlights and brake lights. Our brake lights work with the pedal but not with the hand brake, which will also be repaired during the restoration. New front and rear turn signals will be installed as well.

  Tip: Before you start any motorcycle restoration project, you should hit all the bolts and fasteners with a rust eater product, which penetrates the problem, and give it some time to work. This will stop the bolts from being frozen together, and it'll prevent you from breaking off the heads. And plastic freezer bags or boxes are great for storing and labeling parts.

  And while you're bagging the parts you also want to keep the fasteners with the parts they come off of, and a great way to do that is to get some masking tape and wrap it around the fasteners (figure E). Plastic zip ties work beautifully for keeping parts together as well. These ideas will help to keep the parts organized for later usage during the restoration process.

Now that it's been determined that the project Harley-Davidson is safe enough for a test, it's time to do a more thorough evaluation to analyze the components and plan the restoration.

In the next segment we'll do a chassis dynamometer test to simulate actual driving conditions as well as run the bike under regular driving stresses to further determine the restoration plan.

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