DIY Network

'48 Indian Motorcycle: Front Brake Overhaul The '48 Indian Chief restoration begins with a front brake overhaul. From "Classic Rides" episode DCLR-302

One of the things Chris Matthews, an antique motorcycle expert, noticed during his test ride on the '48 Indian Chief was that the front brake didn't work that well.

Since just about everyone, except maybe Ettore Bugatti, considers brakes to be an important feature on a motor vehicle, this will be the first upgrade.

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	Host Craig Reynolds (background) and Chris Matthews kick off the restoration by overhauling the front brake.
	New brake shoes, seen here, will be installed.
	Chris Matthews says the front brake assembly for the Indian isn't overly complicated.
	After a little grinding the shoes are a perfect fit on the backing plate.
	Figure A

Material/Tools for all Projects:

1948 Indian Chief Motorcycle
complete set of shop tools
bike jack

Materials/Tools for Brake Overhaul:

complete set of wrenches: SAE or Metric
brass hammer
set of Allen wrenches: SAE or Metric
bench grinder or sander
pliers
new brake shoes
brake spring kit

1. Lay the wheel assembly, with the brake drum facing up, out on a level surface.

2. The backing plate, which the shoes and springs mount to, is removed from the drum by slowly pulling up on it and walking it out. Sometimes if the shoes are tight or there is a build up of brake dust this process can require some additional muscle or prying.

3. The shoes are held to the backing plate by two return springs, one end of these simply clip to each shoe and keep tension. Using pliers, pull one end of the spring off each shoe, being careful in the process as sometimes they can jump out.

4. The old shoes can now be removed.

5. Before installing the new shoes, it's a good idea to grind a little material off of the sides of the mounting points. This will prevent any binding. Use a bench grinder and take off a little material on the edges of the shoe.

6. Time for installation. Lay the new shoes on the brake backing plate, making sure the actuating lever is in the correct position.

7. While holding the shoes in place, clip one end of a return spring to a shoe and then use pliers to stretch and clip the other end of the spring to the opposite shoe (figure A). Repeat this process with the other spring.

8. The backing plate and shoes can now slide into the drum.

RESOURCES :

Welders
Lincoln Electric
Website: www.lincolnelectric.com

Kiwi Indian
Website: www.kiwi-indian.com

V-Twin Mfg.
Rims, Spokes, Hubs, Tire Irons and Truing Stand
Website: www.vtwinmfg.com

Motorcycle Lift
Handy Lift
Website: www.handy-lift.com

Various Tools
Eastwood
Website: www.eastwoodco.com

Hepavac Asbestos Vacuum
Bullseye
Website: www.bullseyecorp.com

Parts Washer
Safety Kleen
Website: www.safety-kleen.com

Chrome Polish
G & H Metal Finishers
282 Dakota St.
Paterson, NJ 07503

Belt Grinder
Ellis Manufacturing
Website: www.ellissaw.com

Powder Coating Shop
Best Signs
Phone: 865-922-5247
E-mail: bestsigns@tds.net

Coker Classic White Wall Tires, Tubes and Spoke Covers
Coker Tires
Website: www.coker.com