DIY Network

Test Drive and Restoration Plan From "Classic Rides" episode DCLR-101

Host Kevin Tetz takes the project Harley-Davidson Electra Glide on a test run in this segment.

Now that the project Harley-Davidson 1965 Electra Glide has been fully evaluated in the first two segments, it's time for host Kevin Tetz to take the bike on a test drive.

It doesn't ride too well, but at least it starts and goes in gear! You can't really know how things are going to work together until the bike can be run for a long period of time, and the best way to do this is with a chassis dynamometer.

The chassis dynamometer (also known as "dyno") will simulate actual driving conditions and will reveal much about the bike, including the horsepower, torque and air-to-fuel mixture.

Note: This test will cost approximately $50 and it can be done at a local Harley-Davidson dealership.

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Chassis Dynamometer Test

Our Harley expert and restoration cohort, Bill "Dunk" Dunkelberger, who has been working on Harley-Davidsons since 1980 and has been a master Harley-Davidson mechanic since 1990, explains how the chassis dynamometer test works:

• A dyno run measures the torque and horsepower that the motor is putting out to the rear wheel.

• The piece that's in the tailpipe is the sniffer (figure A), which determines the air-to-fuel mixture. This reveals whether the bike is burning clean, pollutant-free air -- the emissions aspect in other words.

• The clamps seen here (figure B) are the pickups for the spark plugs and two other clamps ground everything. The positive is clamped to the spark-plug wire, which leads to the dyno. Once everything is strapped down and hooked up, Dunk starts the engine and runs the bike through all the gears to test each level (figure C).

Figure A

Figure B

Figure C

Figure D

Dyno Test Results

Our host noticed two things right off the bat:

1. The rear tire was out of balance and wobbling like crazy.

2. He was smelling gasoline fumes that were richer than usual, which means the air-fuel mixture started our lean and went rich. Running rich means the bike is burning too much fuel for the air mixture, which will lead to losing horsepower and torque.

Note: In a stock format the bike should produce approximately 45 foot-pounds of torque and about 30 horsepower, which means the project bike has some room for improvement according to the dyno test (figure D).

	Figure E
	Figure F
	Figure G

Restoration Plan

Now that the bike has been put through a thorough evaluation, test drive and dyno test, it's finally time for the restoration plan, and our host goes over this with Dunk:

• New high-performance carburetor. And on this particular model the best one available would be an S & S model "E" carburetor (figure E). It's considered the best because it flows the most air for this particular motor.

• The actual power output involves more than just the carburetor; it also involves the cam and for this project an upgraded cam will complement the new carburetor. This will supply more torque and horsepower -- and it will be more fuel-efficient, which will help on emissions.

  Note: This will definitely provide a better seat-of-the-pants feel during a ride on the Electra Glide.

• The exhaust (figure F) head pipe will remain on this bike, but Dunk suggests pulling the mufflers back past the end of the saddlebags to "show" them off. Also, this particular bike has a duel-exhaust system and you'll want to keep the originality in tact.

• The tires will be replaced with correct whitewalls (figure G), which are a "hot" item -- especially on a classic such as the Electra Glide.

• New petcock.

• Replace fuel lines and connectors as necessary.

• Replace cables as necessary.

• Replace the saddlebags.

• Polish the aluminum and other metal parts.

• Replace and paint gas tanks.

Figure H

The overall plan is to keep consistent with the original design of the 1965 Electra Glide, tune it up, polish it up and upgrade it where possible without changing the look of this classic American ride.

"There is nothing like the sound of a well-tuned panhead," Dunk said. "A panhead has its own unique sound."

Note: The term "panhead" (figure H) refers to the shape of the Harley-Davidson valve covers, which look like a cake pan.

In the final segment of this first episode Kevin and Dunk begin the restoration by stripping the bike!

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